Cylinder Head

WARNING: This page is about a different car, the 2009 Ford Pickup, 2009 Ford F550 Super Duty, 2009 Ford F450 Super Duty, and 2009 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Special Tools

Illustration	Tool Name	Tool Number
Courtesy of FORD MOTOR CO.	Alignment Pins, Cylinder Head	303-1040 (SR-015486)
Courtesy of FORD MOTOR CO.	Compressor, Valve Spring	303-1039
Courtesy of FORD MOTOR CO.	Engine Lifting Bracket	303-F047 (014-00073) or equivalent
Courtesy of FORD MOTOR CO.	Fan Clutch Nut Wrench	303-214 (T83T-6312-B)
Courtesy of FORD MOTOR CO.	Fan Pulley Holding Wrench	303-478 (T94T-6312-AH)
Courtesy of FORD MOTOR CO.	Holding Tool, Crankshaft	303-448 (T93P-6303-A)
Courtesy of FORD MOTOR CO.	Installer, Crankshaft Front Seal	303-635
Courtesy of FORD MOTOR CO.	Installer, Crankshaft Vibration Damper	303-102 (T74P-6316-B)
Courtesy of FORD MOTOR CO.	Installer, Front Cover Seal	303-335 (T88T-6701-A)
Courtesy of FORD MOTOR CO.	Remover/Installer, Cylinder Head	303-572 (T97T-6000-A)

General Equipment

Hydraulic Chain Tensioner Retaining Clip 1L3Z-6P250-AA

Material

Item	Specification
Motorcraft Metal Surface Prep ZC-31-A	-
Motorcraft Premium Gold Engine Coolant with Bittering Agent (bittered in US only) VC-7-B (US); CVC-7-A (Canada); or equivalent (yellow color)	WSS-M97B51-A1
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalent	WSS-M2C930-A
Silicone Brake Caliper Grease and Dielectric Compound XG-3-A	ESE-M1C171-A
Silicone Gasket and Sealant TA-30	WSE-M4G323-A4
Silicone Gasket Remover ZC-30	-

All cylinder heads

NOTE: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore, or engine damage may occur.

NOTE: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry or engine damage may occur.

NOTE: The cylinder head bolts must be discarded and new bolts installed or engine damage may occur. 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, RH similar.

Using the Cylinder Head Alignment Pins, position the cylinder head gaskets and cylinder heads over the dowels and install the 24 cylinder head bolts loosely.

Fig 1: Installing Cylinder Head Bolts

Courtesy of FORD MOTOR CO.

NOTE: Be sure to tighten the bolts in 3 stages.

Tighten the bolts in the sequence shown.
- 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: Tightening Bolts In Sequence

Courtesy of FORD MOTOR CO.

NOTE: LH shown, RH similar.

Install the cylinder block drain plugs.
- Tighten to 24 Nm (18 lb-ft).

Fig 3: Locating Cylinder Block Drain Plug

Courtesy of FORD MOTOR CO.

NOTE: The engine support insulator bracket bolts must be discarded and new bolts installed or damage to the engine may occur. They are a tighten-to-yield design and cannot be reused.

NOTE: Clean the engine support insulator bracket mounting surface 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.

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 4: Locating Engine Support Insulator Bracket Bolts

Courtesy of FORD MOTOR CO.

LH cylinder head

Remove the Cylinder Head Remover/Installer from the LH cylinder head.

Fig 5: Identifying Special Tool (303-572) Onto Cylinder Head

Courtesy of FORD MOTOR CO.

NOTE: If the components are to be reinstalled, they must be installed into their original locations or damage to the engine may occur.

Install the hydraulic lash adjusters into the LH cylinder head.
- Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.

Fig 6: Identifying Hydraulic Lash Adjusters

Courtesy of FORD MOTOR CO.

Install 10 new exhaust manifold-to-cylinder head studs.
- Tighten to 12 Nm (106 lb-in).

Fig 7: Locating Exhaust Manifold-To-Cylinder Head Studs

Courtesy of FORD MOTOR CO.

Position 2 new gaskets, the LH exhaust manifold and tighten the 10 new nuts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).

Fig 8: Identifying Tightening Sequence For LH Exhaust Manifold Bolts

Courtesy of FORD MOTOR CO.

Position the exhaust manifold heat shield and install the 3 bolts.
- Tighten to 14 Nm (124 lb-in).

Fig 9: Locating Bolts On Exhaust Manifold Heat Shield

Courtesy of FORD MOTOR CO.

RH cylinder head

Remove the Cylinder Head Remover/Installer from the RH cylinder head.

Fig 10: Identifying Special Tool (303-572) On Cylinder Head

Courtesy of FORD MOTOR CO.

NOTE: If the components are to be reinstalled, they must be installed into their original locations or damage to the engine may occur.

Install the hydraulic lash adjusters into the RH cylinder head.
- Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.

Fig 11: Identifying Hydraulic Lash Adjusters

Courtesy of FORD MOTOR CO.

Install 10 new exhaust manifold-to-cylinder head studs.
- Tighten to 12 Nm (106 lb-in).

Fig 12: Locating Exhaust Manifold-To-Cylinder Head Studs

Courtesy of FORD MOTOR CO.

Position 2 new gaskets, the RH exhaust manifold and tighten the 10 new nuts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).

Fig 13: Identifying Tightening Sequence For RH Exhaust Manifold Bolts

Courtesy of FORD MOTOR CO.

Position the exhaust manifold heat shield and install the 2 bolts.
- Tighten to 14 Nm (124 lb-in).

Fig 14: Locating Bolts On Exhaust Manifold Heat Shield

Courtesy of FORD MOTOR CO.

Install the heater coolant tube stud bolt.
- Tighten to 10 Nm (89 lb-in).

Fig 15: Identifying Coolant Tube Stud Bolt

Courtesy of FORD MOTOR CO.

All cylinder heads

NOTE: If the components are to be reinstalled, they must be installed into their original locations or damage to the engine may occur.

NOTE: Camshaft shown installed to clarify camshaft roller follower position.

NOTE: Lubricate the camshaft roller followers with clean engine oil prior to installation.

Install only the identified camshaft roller followers onto the RH cylinder head.

Fig 16: Installing Identified Camshaft Roller Followers Onto RH Cylinder Head

Courtesy of FORD MOTOR CO.

NOTE: If the components are to be reinstalled, they must be installed into their original locations or damage to the engine may occur.

NOTE: Camshaft shown installed to clarify camshaft roller follower position.

NOTE: Lubricate the camshaft roller followers with clean engine oil prior to installation.

Install only the identified camshaft roller followers onto the LH cylinder head.

Fig 17: Locating LH Camshaft Roller Followers

Courtesy of FORD MOTOR CO.

Install the LH and RH camshafts.
- Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.
Install the 6 LH and 6 RH camshaft bearing caps in their original locations.
- Lubricate the camshaft bearing caps with clean engine oil.
- Position the 2 front camshaft bearing caps.
- Position the remaining 10 camshaft bearing caps.
- Install the 24 bolts loosely.
Tighten the 12 LH camshaft bearing cap bolts in 2 stages:
- Stage 1: Tighten to 8 Nm (71 lb-in) in the sequence shown.
- Stage 2: Tighten an additional 45 degrees.

Fig 18: Tightening LH Camshaft Bearing Cap Bolts In Sequence

Courtesy of FORD MOTOR CO.

Tighten the 12 RH camshaft bearing cap bolts in 2 stages:
- Stage 1: Tighten to 8 Nm (71 lb-in) in the sequence shown.
- Stage 2: Tighten an additional 45 degrees.

Fig 19: Identifying RH Camshaft Bearing Cap Bolt Removal/Installation Sequence

Courtesy of FORD MOTOR CO.

Install the balance shaft drive gear onto the LH camshaft.
Install both camshaft sprockets and camshaft sprocket bolts finger-tight.

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.

Using a vise, compress the tensioner plunger.

Fig 20: Compressing Tensioner Plunger

Courtesy of FORD MOTOR CO.

Install a retaining clip on the tensioner to hold the plunger in during installation.

Fig 21: Identifying Retaining Clip on Tensioner

Courtesy of FORD MOTOR CO.

NOTE: There are 61 links in each timing chain.

If copper links are not visible, mark 2 links on one end and 1 link on the other end, and use as timing marks.

Fig 22: Locating Timing Chain Marks

Courtesy of FORD MOTOR CO.

Install the timing chain guides and the 4 bolts.
- Tighten to 10 Nm (89 lb-in).

Fig 23: Locating Timing Chain Guides Bolts

Courtesy of FORD MOTOR CO.

Position the camshafts.
1. Rotate the LH camshaft until the timing mark is at approximately 12 o'clock.
2. Rotate the RH camshaft until the timing mark is at approximately 11 o'clock.

Fig 24: Identifying LH And RH Camshaft Timing Mark Position

Courtesy of FORD MOTOR CO.

Position the crankshaft with the Crankshaft Holding Tool, then remove the tool.

Fig 25: Positioning Crankshaft With Special Tool (303-448)

Courtesy of FORD MOTOR CO.

Install the crankshaft sprocket, marking sure the flange faces forward.

Fig 26: Identifying Crankshaft Sprocket

Courtesy of FORD MOTOR CO.

Install the lower end of the LH timing chain, aligning the timing marks.

Fig 27: Aligning Timing Mark Of Crankshaft Sprocket With Single Copper Link On Chain

Courtesy of FORD MOTOR CO.

NOTE: Be sure the upper half of the timing chain is below the tensioner guide dowel.

Install the LH timing chain on the camshaft sprocket with the 2 chain (marked) links and the timing marks aligned.

Fig 28: Aligning Timing Marks On Sprocket With Marked Chain Links

Courtesy of FORD MOTOR CO.

NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.

Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner and the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).

Fig 29: Identifying LH Timing Chain Tensioner & Tensioner Arm

Courtesy of FORD MOTOR CO.

NOTE: Be sure the chain link and crankshaft sprocket timing marks are aligned.

NOTE: The lower half of the timing chain must be positioned above the dowel.

Install the RH (outer) timing chain on the crankshaft sprocket.

Fig 30: Aligning Timing Mark On Crankshaft Sprocket With Single Copper Chain Link

Courtesy of FORD MOTOR CO.

Position the timing chain on the camshaft sprocket. Make sure the 2 copper-colored (marked) links align with the camshaft sprocket timing mark.

Fig 31: Aligning Copper-Colored (Marked) Links With Camshaft Sprocket Timing Mark

Courtesy of FORD MOTOR CO.

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 32: Identifying RH Timing Chain Tensioner, Tensioner Arm And Bolts

Courtesy of FORD MOTOR CO.

Remove the retaining clips from the RH and LH timing chain tensioners.

Fig 33: Identifying Retaining Clip And Timing Chain Tensioner

Courtesy of FORD MOTOR CO.

Check for correct alignment of all timing marks.

Fig 34: Identifying Alignment Of All Timing Marks

Courtesy of FORD MOTOR CO.

Install the crankshaft sensor ring on the crankshaft.

Fig 35: View Of Crankshaft Sensor Ring At Crankshaft

Courtesy of FORD MOTOR CO.

NOTE: Only use hand tools to tighten the camshaft sprocket bolt or damage to the camshaft or camshaft sprocket may occur.

Tighten the RH camshaft sprocket bolt in 2 stages:
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten an additional 90 degrees.

Fig 36: Identifying Camshaft Sprocket Bolt

Courtesy of FORD MOTOR CO.

NOTE: Only use hand tools to tighten the camshaft sprocket bolt or damage to the camshaft or camshaft sprocket may occur.

Tighten the LH camshaft sprocket bolt in 2 stages:
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten an additional 90 degrees.

Fig 37: Identifying LH Camshaft Sprocket Bolt

Courtesy of FORD MOTOR CO.

Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.

Fig 38: Crankshaft Positioned With Keyway At 6 O'clock Position

Courtesy of FORD MOTOR CO.

Remove the 2 bolts and the middle balance shaft bearing support and camshaft bearing cap assembly.

Fig 39: Identifying Bolts And Camshaft Bearing Cap

Courtesy of FORD MOTOR CO.

NOTE: If the components are to be reinstalled, they must be installed into their original locations or damage to the engine may occur.

NOTE: Do not allow the valve keepers to fall off 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 down on the valve while compressing the spring.

Using the Valve Spring Compressor, install the roller follower.
- Lubricate the camshaft roller follower with clean engine oil prior to installation.

Fig 40: Installing Roller Follower

Courtesy of FORD MOTOR CO.

Position the camshaft bearing cap and install the 2 bolts in 2 stages:
- Stage 1: Tighten to 8 Nm (71 lb-in).
- Stage 2: Tighten an additional 45 degrees.

Fig 41: Identifying Bolts And Camshaft Bearing Cap

Courtesy of FORD MOTOR CO.

Remove the 2 bolts and the rear balance shaft bearing support and camshaft bearing cap assembly.

Fig 42: Identifying Bolts And Camshaft Bearing Cap

Courtesy of FORD MOTOR CO.

NOTE: If the components are to be reinstalled, they must be installed into their original locations or damage to the engine may occur.

NOTE: Do not allow the valve keepers to fall off 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 down on the valve while compressing the spring.

Using the Valve Spring Compressor, install the roller follower.
- Lubricate the camshaft roller follower with clean engine oil prior to installation.

Fig 43: Installing Roller Follower

Courtesy of FORD MOTOR CO.

Position the camshaft bearing cap and install the 2 bolts in 2 stages:
- Stage 1: Tighten to 8 Nm (71 lb-in).
- Stage 2: Tighten an additional 45 degrees.

Fig 44: Identifying Bolts And Camshaft Bearing Cap

Courtesy of FORD MOTOR CO.

NOTE: If the components are to be reinstalled, they must be installed into their original locations or damage to the engine may occur.

NOTE: Do not allow the valve keepers to fall off 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 down on the valve while compressing the spring.

Using the Valve Spring Compressor, install all of the remaining camshaft roller followers.
- Lubricate the camshaft roller followers with clean engine oil prior to installation.

Fig 45: Compressing Spring Using Special Tool (303-1039)

Courtesy of FORD MOTOR CO.

Rotate the crankshaft counterclockwise and position the crankshaft keyway at the 11 o'clock position.
Lubricate the balance shaft journals with clean engine oil.

NOTE: Camshaft sprocket removed from art for clarity.

Position the balance shaft on the journals and align the timing mark on the balance shaft with the camshaft timing mark as shown.

Fig 46: Positioning Balance Shaft On Journals & Aligning Timing Mark On Balance Shaft With Camshaft Timing Mark

Courtesy of FORD MOTOR CO.

NOTE: The balance shaft bearing caps must be installed into their original locations or engine damage may occur.

Position the 3 balance shaft bearing caps and install the 6 bolts and tighten in the sequence shown.
- Tighten to 10 Nm (89 lb-in).

Fig 47: Identifying Balance Shaft Bolt Loosening/Tightening Sequence

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 motorcraft 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.

Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface at the locations shown.

Fig 48: Applying Bead of Silicone Gasket And Sealant Along Cylinder Head-To-Cylinder Block Surface And Oil Pan-To-Cylinder Block Surface

Courtesy of FORD MOTOR CO.

Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the 15 fasteners finger-tight.

Fig 49: Installing Engine Front Cover Gasket

Courtesy of FORD MOTOR CO.

Tighten the 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	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 and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
12	W709573	Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
13	W709573	Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
14	W709573	Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
15	W709573	Stud and Washer, Hex Head Pilot, M8 x 1.25 x 56

Fig 50: Tightening Front Cover Fasteners In Sequence

Courtesy of FORD MOTOR CO.

Install the front 4 oil pan bolts in the sequence shown, in 2 stages:
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten an additional 60 degrees.

Fig 51: Identifying Tightening Sequence Of Front Oil Pan Bolts

Courtesy of FORD MOTOR CO.

NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.

Install the Camshaft Position (CMP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).

Fig 52: Locating Camshaft (CMP) Sensor Bolt

Courtesy of FORD MOTOR CO.

Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil.

Fig 53: Locating Crankshaft Front Seal

Courtesy of FORD MOTOR CO.

Using the Crankshaft Vibration Damper Installer, Front Cover Seal Installer and Crankshaft Front Seal Installer, install a new crankshaft front seal.

Fig 54: Installing Crankshaft Front Seal Using Special Tools (303-102, 303-335, 303-635)

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 motorcraft 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.

Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.

Fig 55: Applying Silicone Gasket And Sealant To Woodruff Key Slot On Crankshaft Pulley

Courtesy of FORD MOTOR CO.

Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.

Fig 56: Installing Crankshaft Pulley Using Special Tool (303-102)

Courtesy of FORD MOTOR CO.

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 57: Identifying Crankshaft Pulley Bolt Tightening Sequence

Courtesy of FORD MOTOR CO.

Position the Crankshaft Position (CKP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).

Fig 58: Locating Crankshaft Position (CKP) Sensor Bolt

Courtesy of FORD MOTOR CO.

Position the accessory drive belt tensioner and install the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).

Fig 59: Identifying Accessory Drive Belt Tensioner Bolts

Courtesy of FORD MOTOR CO.

Install the accessory drive belt idler pulley, the coolant pump pulley and the 5 bolts.
- Tighten to 25 Nm (18 lb-ft).

Fig 60: Identifying Coolant Pump Pulley Bolts And Idler Pulley Bolt

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.

Clean the valve cover mating surface with silicone gasket remover and motorcraft metal surface prep. Follow the directions on the packaging.

NOTE: If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and motorcraft 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.

Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.

Fig 61: Identifying Silicone Gasket And Sealant Application Points

Courtesy of FORD MOTOR CO.

Position the RH valve cover and new gasket on the cylinder head and tighten the 16 fasteners in the sequence shown.
- Tighten to 10 Nm (89 lb-in).

Fig 62: Identifying Valve Cover Fasteners Loosening/Tightening Sequence

Courtesy of FORD MOTOR CO.

Clean the valve cover mating surface with silicone gasket remover and motorcraft metal surface prep. Follow the directions on the packaging.

Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.

Fig 63: Identifying Silicone Gasket And Sealant Application Points

Courtesy of FORD MOTOR CO.

Position the LH valve cover and new gasket on the cylinder head and tighten the 17 fasteners in the sequence shown.
- Tighten to 10 Nm (89 lb-in).

Fig 64: Identifying Valve Cover Fasteners Tightening Sequence

Courtesy of FORD MOTOR CO.

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 65: Locating Rear Oil Level Indicator Tube Bolt

Courtesy of FORD MOTOR CO.

Install the oil level indicator and tube front bolt.
- Tighten to 25 Nm (18 lb-ft).

Fig 66: Locating Front Oil Level Indicator Tube Bolt

Courtesy of FORD MOTOR CO.

Position the electrical harness on the engine assembly and connect the engine wiring harness retainers to the valve cover studs.
Connect the CKP sensor electrical connector.

Fig 67: Locating CKP Sensor Electrical Connector And Harness Retainer

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: Apply a light coat of dielectric compound to the inside of the ignition coil boots prior to installation.

Install the 10 ignition coils and the 10 bolts.
- Tighten to 6 Nm (53 lb-in).

Fig 68: Locating Ignition Coils Bolts

Courtesy of FORD MOTOR CO.

Connect the 10 ignition coil electrical connectors.

Fig 69: Locating Ignition Coil Electrical Connectors

Courtesy of FORD MOTOR CO.

Install the LH radio ignition interference capacitor and the nut.
- Tighten to 25 Nm (18 lb-ft).

Fig 70: Identifying LH Radio Ignition Interference Capacitor And Stud Bolt

Courtesy of FORD MOTOR CO.

Connect the Engine Oil Pressure (EOP) switch electrical connector.

Fig 71: Identifying Engine Oil Pressure (EOP) Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

Connect the Cylinder Head Temperature (CHT) sensor electrical connector.

Fig 72: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

Install the RH radio ignition interference capacitor and the nut.
- Tighten to 25 Nm (18 lb-ft).

Fig 73: Identifying RH Radio Ignition Interference Capacitor Stud Bolt

Courtesy of FORD MOTOR CO.

Connect the CMP sensor electrical connector.

Fig 74: Identifying RH CMP Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

NOTE: The large clutch assembly nut has a RH thread and must be rotated clockwise to install it.

Using the Fan Pulley Holding Wrench and the Fan Clutch Nut Wrench, install the engine cooling fan onto the cooling pump pulley.
- Tighten to 133 Nm (98 lb-ft).

Fig 75: Fan Clutch Assembly Nut - 6.8L

Courtesy of FORD MOTOR CO.

Using a suitable floor crane, remove the engine from the engine stand.
Lower and support the engine assembly on wood blocks.
Install the Engine Lifting Bracket.

Fig 76: Identifying Special Tool (303-F047)

Courtesy of FORD MOTOR CO.

Using a suitable floor crane, raise the engine.
Install the flexplate or flywheel and the 8 bolts in the sequence shown.
- Tighten to 80 Nm (59 lb-ft).

Fig 77: Identifying Tightening Sequence For Flexplate Or Flywheel Bolts

Courtesy of FORD MOTOR CO.

Install the engine. For additional information, refer to Engine .