Steps 1-40

Cylinder Head

















Installation

Both cylinder heads

1. NOTE: The gasket sealing surfaces on the cylinder head and cylinder block must be clean. For additional information, refer to Cylinder Head Cylinder Head - Removal in the Removal portion.

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

NOTE: The new gasket has a film coating which is crucial to the gasket's ability to seal correctly. Do not scratch the gasket.

NOTE: RH head gasket shown, LH head gasket similar.

Install the new head gasket over the dowel pins.





2. NOTE: Cylinder head machining or milling is not authorized by the Ford Motor Company. Cylinder head flatness must be within 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area.

NOTE: The gasket sealing surfaces on the cylinder head and cylinder block must be clean. For additional information, refer to Cylinder Head Cylinder Head - Removal in the Removal portion.

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

NOTE: Do not allow the dowels to scratch the sealing surface of the cylinder head during cylinder head installation.

NOTE: RH cylinder head shown, LH cylinder head similar.

Install the cylinder head on the dowels and the head gasket. Loosely install new bolts.





3. Tighten the cylinder head bolts in 6 stages, in the sequence shown.
- Stage 1: Tighten to 40 Nm (30 lb-ft).

- Stage 2: Tighten an additional 90 degrees (one-quarter turn).

- Stage 3: Loosen a minimum of one full turn (360 degrees).

- Stage 4: Tighten to 40 Nm (30 lb-ft).

- Stage 5: Tighten an additional 90 degrees (one-quarter turn).

- Stage 6: Tighten an additional 90 degrees (one-quarter turn).





4. Remove the Cylinder Head Remover/Installer from both ends of the cylinder head.





LH cylinder head

5. NOTE: Lubricate the O-ring seal with clean engine oil.

Install a new O-ring seal on the oil level indicator tube and install the oil level indicator tube and bolt.

- Tighten to 10 Nm (89 lb-in).





6. Install the 8 new LH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).

7. Install a new LH exhaust manifold gasket the LH exhaust manifold and 8 new nuts.
- Tighten to 20 Nm (177 lb-in) in the sequence shown.





RH cylinder head

8. Install the 8 new RH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).

9. Install a new RH exhaust manifold gasket the RH exhaust manifold and 8 new nuts.
- Tighten to 20 Nm (177 lb-in) in the sequence shown.





Engines with ratcheting timing chain tensioners

10. NOTICE: Timing chain procedures must be followed exactly or damage to valves and pistons will result.

NOTICE: Do not compress the ratchet assembly. This will damage the ratchet assembly.

NOTE: LH shown, RH similar.

Compress each tensioner plunger, using an edge of a vise.





11. Using a small screwdriver or pick, push back and hold the ratchet mechanism.





12. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.





13. Install a paper clip into the hole of each tensioner housing to hold the ratchet assembly and plunger in during installation.
- Remove the tensioner from the vise.





Engines with non-ratcheting timing chain tensioners

14. NOTICE: If one or both tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected 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.

Inspect the RH and LH timing chain tensioners.

- Install new tensioners as necessary.

15. NOTICE: Timing chain procedures must be followed exactly or damage to valves and pistons will result.

NOTE: LH shown, RH similar.

Compress each tensioner plunger, using an edge of a vise.





16. Install a Hydraulic Chain Tensioner Retaining Clip on the tensioner to hold the plunger in during installation.





Both cylinder heads

17. If the colored links are not visible, mark one link on one end and one link on the other end, and use as timing marks.





18. Using the Crankshaft Holding Tool, position the crankshaft.
- Remove the Crankshaft Holding Tool after crankshaft positioning.





19. Install the crankshaft sprocket, making sure the flange faces forward.





20. Install the timing chain guides.

1. Position the LH timing chain guide.

2. Install and tighten the LH bolts to 10 Nm (89 lb-in).

3. Position the RH timing chain guide.

4. Install and tighten the RH bolts to 10 Nm (89 lb-in).





21. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 1 o'clock position.





22. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the colored (marked) link with the timing mark on the sprocket.





23. Install the LH timing chain on the camshaft sprocket, aligning the colored (marked) link with the timing marks on the sprocket.





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

Position the LH timing chain tensioner on the dowel pin and install the LH timing chain tensioner.

- Tighten to 25 Nm (18 lb-ft).





25. Remove the Hydraulic Chain Tensioner Retaining Clip from the LH timing chain tensioner.





26. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the colored (marked) link with the timing mark on the sprocket.





27. Install the RH timing chain on the camshaft sprocket, aligning the colored (marked) link with the timing marks on the sprocket.





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





29. Remove the Hydraulic Chain Tensioner Retaining Clip from the RH timing chain tensioner.





30. Make sure that the colored (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.





31. Rotate the camshaft until the lobe is in the upward position.





32. Install the Valve Spring Compressor Spacer between the valve spring coils to prevent valve stem seal damage.





33. NOTE: Lubricate the hydraulic lash adjusters with clean engine oil.

Install the 16 hydraulic lash adjusters in their original locations (4 shown).





34. NOTE: Lubricate the camshaft roller followers using clean engine oil.

NOTE: Position the cam lobe away from the camshaft roller follower location prior to installing each camshaft roller follower.

Install the camshaft roller follower.

1. Install the Valve Spring Compressor.

2. Compress the valve spring.

3. Install the camshaft roller followers in their original locations.





35. Remove the Valve Spring Compressor Spacer.





36. NOTICE: Only use hand tools when removing or installing the spark plugs, damage may occur to the cylinder head or spark plug.

Install all 8 spark plugs.

- Tighten to 18 Nm (159 lb-in).





37. Install the crankshaft sensor ring.





38. NOTICE: 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. Failure to follow this procedure can cause future oil leakage.

Apply a bead of sealant along the head-to-block surface and the oil pan-to-block surface as specified.





39. 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.





40. Tighten the front cover fasteners in the sequence shown to 25 Nm (18 lb-ft).