Cylinder Head: Installation

All vehicles 

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 that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
NOTE: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.
NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.
1. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block in the following sequence.
   1. Remove any large deposits of silicone or gasket material with a plastic scraper.
   2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.
   3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
   4. Apply metal surface prep, following package directions, to remove any traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
2. Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.
3. Inspect the cylinder head for distortion. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
4. Apply silicone gasket and sealant to the locations shown.
Fig 1: Identifying Silicone Gasket And Sealant Location
Courtesy of FORD MOTOR CO.
5. Install a new head gasket.
NOTE: The cylinder head bolts are a torque-to-yield design and must not be reused. New cylinder head bolts must be installed.
NOTE: Lubricate the bolts with clean engine oil prior to installation.
6. Install the cylinder head and 10 new bolts. Tighten the bolts in the sequence shown in 5 stages:
   • Stage 1: Tighten to 7 Nm (62 lb-in).
   • Stage 2: Tighten to 15 Nm (133 lb-in).
   • Stage 3: Tighten to 45 Nm (33 lb-ft).
   • Stage 4: Turn 90 degrees.
   • Stage 5: Turn an additional 90 degrees.
Fig 2: Identifying Tightening Sequence Of Cylinder Head Bolts
Courtesy of FORD MOTOR CO.

Vehicles with AIR 

7. Position AIR valve bracket and install the 2 bolts.
   • Tighten to 10 Nm (89 lb-in).

All vehicles 

8. Connect the coolant hose to the EGR valve.
9. Connect the EGR valve electrical connector.
10. Connect the ECT electrical connector.
11. Connect the upper radiator hose, coolant bypass hose, heater hose and coolant vent hose to the engine coolant outlet.
12. Attach the EVAP tube bundle retaining clip retaining clip.
Fig 3: Locating Evaporative Emissions (EVAP) Tube Bundle Retaining Clip
Courtesy of FORD MOTOR CO.
NOTE: Coat the valve tappets with clean engine oil prior to installation.
13. Install the valve tappets.
NOTE: Install the camshafts with the alignment slots in the camshafts lined up so the Camshaft Alignment Plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the removal procedure. Rotating the camshafts when the timing chain is removed, or installing the camshafts 180 degrees out of position can cause severe damage to the valves and pistons.
NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil.
14. Install the camshafts and bearing caps in their original location and orientation. Tighten the bearing caps in the sequence shown in 3 stages:
    • Stages 1: Tighten the camshaft bearing cap bolts until finger tight.
    • Stages 2: Tighten to 7 Nm (62 lb-in).
    • Stages 3: Tighten to 16 Nm (142 lb-in).
Fig 4: Identifying Tightening Sequence Of Camshaft Bearing Cap Bolts
Courtesy of FORD MOTOR CO.
15. Install the Camshaft Alignment Plate.
Fig 5: Identifying Special Camshaft Tool (303-465)
Courtesy of FORD MOTOR CO.
16. Install the VCT solenoid and bolt.
    • Tighten to 10 Nm (89 lb-in).
17. Install the timing drive components. For additional information, refer to Timing Drive Components .
18. Install the engine mount bracket and the 2 nuts.
    • Tighten to 103 Nm (76 lb-ft).
19. Using the Engine Support Bar and Engine Lifting Brackets, lift the engine 25 mm (0.98 in).
Fig 6: Lifting Engine Using Special Tool (303-050, 313-F072)
Courtesy of FORD MOTOR CO.
20. Install the engine mount, nut and 2 bolts.
    • Tighten to 55 Nm (41 lb-ft).
21. Lower the engine 25 mm (0.98 in).
22. Install the engine mount bracket bolt.
    • Tighten to 115 Nm (85 lb-ft).
23. Install the radio frequency interference capacitor and bolt to the engine mount bracket.
    • Tighten to 10 Nm (89 lb-in).

Vehicles with AIR 

24. Install the AIR pump and the 3 bolts.
    • Tighten to 30 Nm (22 lb-ft).
25. Connect the AIR pump electrical connector.

All vehicles 

26. Install the intake manifold. For additional information, refer to Intake Manifold .
27. Install the fuel supply rail. For additional information, refer to FUEL CHARGING AND CONTROLS - 2.3L article.
28. Install the generator. For additional information, refer to CHARGING SYSTEM - GENERAL INFORMATION article.
29. Install the catalytic converter. For additional information, refer to EXHAUST SYSTEM article.
30. Install the degas bottle. For additional information, refer to ENGINE COOLING article.
31. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING article.