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Cylinder Head: Installation

WARNING: This page is about a different car, the 2006 Mercury Grand Marquis and 2006 Ford Crown Victoria. However, it is still accessible from the selected car via links, so may be relevant.

    Both cylinder heads 

    CAUTION: The gasket sealing surfaces on the cylinder head and cylinder block must be clean. For additional information, refer to CYLINDER HEAD  in the Removal portion of this article.
    CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.
    CAUTION: 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.
    Fig 1: Installing Head Gasket Over Dowel Pins
    G04583941Courtesy of FORD MOTOR CO.
  1. Install the new head gasket over the dowel pins.
    2. CAUTION: 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.
    CAUTION: The gasket sealing surfaces on the cylinder head and cylinder block must be clean. For additional information, refer to CYLINDER HEAD  in the Removal portion of this article.
    CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.
    CAUTION: Do not allow the dowels to scratch the sealing surface of the cylinder head during cylinder head installation.
    NOTE: The new cylinder head bolts must be lightly oiled with a rag, and allowed to drain for a few minutes prior to installation.
    NOTE: RH cylinder head shown, LH cylinder head similar.
    Fig 2: Locating Cylinder Head
    G03886030Courtesy of FORD MOTOR CO.
  2. 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 (1/4 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 (1/4 turn).
    • Stage 6: Tighten an additional 90 degrees (1/4 turn).
      Fig 3: Tightening Cylinder Head Bolts In Stages In Sequence
      G04583943Courtesy of FORD MOTOR CO.
  4. Remove the special tools from both ends of the cylinder head.
    Fig 4: Identifying Special Tool (303-572)
    G04671899Courtesy of FORD MOTOR CO.
    5. NOTE: Lubricate the hydraulic lash adjusters with clean engine oil.
    Fig 5: Locating Hydraulic Lash Adjusters
    G04583838Courtesy of FORD MOTOR CO.
  5. Install the hydraulic lash adjusters in their original locations.

    6. LH cylinder head 

    NOTE: Lubricate the O-ring seal with clean engine oil.
  6. 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).
      Fig 6: Installing Oil Level Indicator Tube
      G04583946Courtesy of FORD MOTOR CO.
  7. Install a new LH exhaust manifold gasket the LH exhaust manifold and 8 nuts.
    • Tighten to 25 Nm (18 lb-ft) in the sequence shown.
      Fig 7: Installing LH Exhaust Manifold Gasket LH Exhaust Manifold And Nuts
      G04583947Courtesy of FORD MOTOR CO.

    8. RH cylinder head 

  8. Install a new RH exhaust manifold gasket the RH exhaust manifold and 8 nuts.
    • Tighten to 25 Nm (18 lb-ft) in the sequence shown.
      Fig 8: Installing RH Exhaust Manifold Gasket RH Exhaust Manifold And Nuts
      G04583948Courtesy of FORD MOTOR CO.

    9. Engines with ratcheting timing chain tensioners 

    CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
    CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly.
    NOTE: LH shown, RH similar.
    Fig 9: Compressing Each Tensioner Plunger Using Vise
    G04583949Courtesy of FORD MOTOR CO.
  9. Compress each tensioner plunger, using an edge of a vise.
  10. Using a small screwdriver or pick, push back and hold the ratchet mechanism.
    Fig 10: Pushing Back And Holding Ratchet Mechanism
    G04583950Courtesy of FORD MOTOR CO.
  11. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
    Fig 11: Pushing Ratchet Arm Back Into Tensioner Housing
    G04583951Courtesy of FORD MOTOR CO.
  12. 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.
      Fig 12: Installing Paper Clip Into Hole Of Each Tensioner Housing
      G04583952Courtesy of FORD MOTOR CO.

    13. Engines with non-ratcheting timing chain tensioners 

    CAUTION: If one or both tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. Any cracks, tears, cuts or separation from the tensioner body or permanent compression of the seal bead, will require replacement of the tensioner.
  13. Inspect the RH and LH timing chain tensioners.
    • Install new tensioners as necessary.
    14. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
    NOTE: LH shown, RH similar.
    Fig 13: Compressing Tensioner Plunger
    G03885344Courtesy of FORD MOTOR CO.
  14. Compress each tensioner plunger, using an edge of a vise.
  15. Install a retaining clip on the tensioner to hold the plunger in during installation.
    Fig 14: Identifying Retaining Clip on Tensioner
    G03881580Courtesy of FORD MOTOR CO.

    16. Both cylinder heads 

  16. If the copper links are not visible, mark one link on one end and one link on the other end, and use as timing marks.
    Fig 15: Identifying Timing Chain Copper Links
    G03881581Courtesy of FORD MOTOR CO.
  17. Using the special tool, position the crankshaft.
    • Remove the special tool after crankshaft positioning.
      Fig 16: Positioning Crankshaft
      G04583956Courtesy of FORD MOTOR CO.
  18. Install the crankshaft sprocket, making sure the flange faces forward.
    Fig 17: Identifying Crankshaft Sprocket Flange
    G03881584Courtesy of FORD MOTOR CO.
  19. 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).
      Fig 18: Identifying Timing Chain Guides
      G03962457Courtesy of FORD MOTOR CO.
  20. 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 12 o'clock position.
    Fig 19: Identifying LH And RH Camshaft Timing Mark Position
    G04583473Courtesy of FORD MOTOR CO.
  21. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
    Fig 20: Aligning Copper (Marked) Link With Timing Mark On Crankshaft Sprocket
    G03962459Courtesy of FORD MOTOR CO.
  22. Install the LH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
    Fig 21: Aligning Copper (Marked) Link With Timing Mark On Camshaft Sprocket
    G03962460Courtesy of FORD MOTOR CO.
    23. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
  23. Position the LH timing chain tensioner on the dowel pin and install the LH timing chain tensioner.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 22: Installing LH Timing Chain Tensioner
      G04583962Courtesy of FORD MOTOR CO.
  24. Remove the retaining clip from the LH timing chain tensioner.
    Fig 23: View Of Retaining Clip AndTiming Chain Tensioner
    G03881591Courtesy of FORD MOTOR CO.
  25. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
    Fig 24: Aligning Copper (Marked) Link With Timing Mark On Crankshaft Sprocket
    G03948189Courtesy of FORD MOTOR CO.
  26. Install the RH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
    Fig 25: Aligning Copper (Marked) Link With Timing Mark On Camshaft Sprocket
    G03885941Courtesy of FORD MOTOR CO.
  27. 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).
      Fig 26: Installing RH Timing Chain Tensioner
      G04583966Courtesy of FORD MOTOR CO.
  28. Remove the retaining clip from the RH timing chain tensioner.
    Fig 27: View Of Retaining Clip AndTiming Chain Tensioner
    G03881591Courtesy of FORD MOTOR CO.
  29. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.
    Fig 28: Identifying Copper (Marked) Chain Links And Dots On Crankshaft Sprockets And Camshaft Sprockets
    G03962922Courtesy of FORD MOTOR CO.
  30. Rotate the camshaft until the lobe is in the upward position.
    Fig 29: Rotating Camshaft
    G04583969Courtesy of FORD MOTOR CO.
  31. Install the special tool between the valve spring coils to prevent valve stem seal damage.
    Fig 30: Installing Special Tool Between Valve Spring Coils
    G03962476Courtesy of FORD MOTOR CO.
    32. 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.
  32. Install the camshaft roller follower.
    1. Install the special tool.
    2. Compress the valve spring.
    3. Install the camshaft roller followers in their original location.
      Fig 31: Installing Camshaft Roller Followers In Original Location
      G04583971Courtesy of FORD MOTOR CO.
  33. Remove the special tool.
    Fig 32: Installing Special Tool Between Valve Spring Coils
    G03962476Courtesy of FORD MOTOR CO.
    34. CAUTION: Only use hand tools when removing or installing the spark plugs, damage can occur to the cylinder head or spark plug.
  34. Install all 8 spark plugs.
    • Tighten to 15 Nm (11 lb-ft).
      Fig 33: Removing Spark Plugs
      G04583973Courtesy of FORD MOTOR CO.
  35. Install the crankshaft sensor ring.
    Fig 34: Installing Crankshaft Sensor Ring
    G04583974Courtesy of FORD MOTOR CO.
    36. NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 35: View Of Crankshaft Sensor Ring At Crankshaft
    G04583449Courtesy of FORD MOTOR CO.
  36. Apply a bead of sealant along the head-to-block surface and the oil pan-to-block surface as specified.
  37. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.
    Fig 36: Identifying Engine Front Cover And Alignment Dowels
    G03881967Courtesy of FORD MOTOR CO.
  38. Tighten the front cover fasteners in the sequence shown to 25 Nm (18 lb-ft).
    Fig 37: Tightening Front Cover Fasteners In Sequence
    G04583977Courtesy of FORD MOTOR CO.
  39. Loosely install the bolts, then tighten in 2 stages in the sequence shown.
    • Stage 1: Tighten to 20 Nm (15 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
      Fig 38: Tightening An Additional 90 Degrees
      G04583978Courtesy of FORD MOTOR CO.
    40. NOTE: RH shown, LH similar.
  40. Install the RH and LH engine mounts and the bolts.
    • Tighten to 70 Nm (52 lb-ft).
      Fig 39: Removing LH And RH Engine Mount
      G04583979Courtesy of FORD MOTOR CO.
  41. Lubricate the engine front cover and the front oil seal inner lip with clean engine oil.
    Fig 40: Locating Crankshaft Front Seal
    G03881970Courtesy of FORD MOTOR CO.
  42. Using the special tools, install the front oil seal.
    Fig 41: Installing Crankshaft Front Seal Using Special Tools
    G03919891Courtesy of FORD MOTOR CO.
    43. NOTE: If not secured within 4 minutes, sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 42: Applying Sealant To Woodruff Key Slot On Crankshaft Pulley
    G04583982Courtesy of FORD MOTOR CO.
  43. Apply sealant to the Woodruff key slot on the crankshaft pulley.
  44. Using the special tool, install the crankshaft pulley.
    Fig 43: Installing Crankshaft Pulley
    G04583983Courtesy of FORD MOTOR CO.
    45. NOTE: Use special tool 303-009 or suitable strap wrench to hold the pulley.
  45. Tighten the 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: Rotate an additional 90 degrees (1/4 turn).
      Fig 44: Tightening Crankshaft Pulley Bolt
      G04583984Courtesy of FORD MOTOR CO.
  46. Position the coolant pump pulley on the coolant pump and install the bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 45: Positioning Coolant Pump Pulley On Coolant Pump
      G04583985Courtesy of FORD MOTOR CO.
  47. Install the accessory drive belt idler pulley and bolt.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 46: Installing Accessory Drive Belt Idler Pulley
      G04583986Courtesy of FORD MOTOR CO.
    48. NOTE: If not secured within 4 minutes, sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 47: Applying Sealant In Places Where Engine Front Cover Meets Cylinder Head
    G04583987Courtesy of FORD MOTOR CO.
  48. Apply sealant in 2 places where the engine front cover meets the cylinder head.
  49. Install the new valve cover gasket into the valve cover and position on the cylinder head. Tighten the bolts in the sequence shown.
    • Tighten to 10 Nm (89 lb-in).
      Fig 48: Tightening Bolts In Sequence
      G04583988Courtesy of FORD MOTOR CO.
    50. NOTE: If not secured within 4 minutes, sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 49: Applying Sealant In Places Where Engine Front Cover Meet Cylinder Head
    G04583989Courtesy of FORD MOTOR CO.
  50. Apply sealant in 2 places where the engine front cover meets the cylinder head.
  51. Install the gasket into the valve cover and position on the cylinder head. Tighten the bolts in the sequence shown.
    • Tighten to 10 Nm (89 lb-in).
      Fig 50: Tightening Bolts In Sequence
      G04583990Courtesy of FORD MOTOR CO.
  52. Inspect the O-ring seals. Install new seals if necessary.
    Fig 51: Inspecting O-Ring Seals
    G04583991Courtesy of FORD MOTOR CO.
  53. Install the coolant bypass tube.
    Fig 52: Installing Coolant Bypass Tube
    G04583992Courtesy of FORD MOTOR CO.
  54. Install the ground strap on the rear of the RH cylinder head.
    1. Install the stud bolt and tighten to 25 Nm (18 lb-ft).
    2. Install the ground strap.
    3. Install the retaining nut and tighten to 10 Nm (89 lb-in).
      Fig 53: Installing Retaining Nut
      G04583993Courtesy of FORD MOTOR CO.
    55. NOTE: Align the gasket locator tabs to slots in cylinder head.
    Fig 54: Installing New Intake Manifold Gaskets
    G04583994Courtesy of FORD MOTOR CO.
  55. Install new intake manifold gaskets.
  56. Install the intake manifold and hand-tighten the bolts at the locations shown.
    Fig 55: Installing Intake Manifold
    G04583995Courtesy of FORD MOTOR CO.
  57. Install the 8 ignition coils and tighten the 8 bolts.
    • Tighten to 6 Nm (53 lb-in).
      Fig 56: Installing Ignition Coils
      G04583996Courtesy of FORD MOTOR CO.
  58. Install the intake manifold bracket and loosely install the bolt and the stud.
    Fig 57: Installing Intake Manifold Bracket
    G04583997Courtesy of FORD MOTOR CO.
  59. Install the thermostat.
    Fig 58: Installing Thermostat
    G04583998Courtesy of FORD MOTOR CO.
  60. Install the coolant outlet adapter and loosely install the 2 bolts.
    Fig 59: Installing Coolant Outlet Adapter
    G04583999Courtesy of FORD MOTOR CO.
  61. Tighten the bolts in the sequence shown.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 60: Tightening Intake Manifold Bolts In Sequence
      G04584000Courtesy of FORD MOTOR CO.
  62. Tighten the stud.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 61: Tightening Stud
      G04584001Courtesy of FORD MOTOR CO.
  63. Tighten the bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 62: Installing Coolant Outlet Adapter
      G04584002Courtesy of FORD MOTOR CO.
  64. Connect the exhaust gas recirculation (EGR) tube to the EGR valve.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 63: Connecting EGR System Module Tube Nut From EGR System Module
      G04584003Courtesy of FORD MOTOR CO.
  65. Connect the EGR tube-to-exhaust manifold connector.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 64: Connecting Exhaust Gas Recirculation (EGR) Tube From Exhaust Manifold
      G04584004Courtesy of FORD MOTOR CO.
  66. Position the fuel charging wiring at 2 locations at the back of the intake manifold.
  67. Install the generator and bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 65: Installing Generator And Bolts
      G04584005Courtesy of FORD MOTOR CO.
  68. Connect the throttle control and the throttle position (TP) sensor electrical connector.
    Fig 66: Locating Throttle Control And Throttle Position (TP) Sensor Electrical Connectors
    G03881492Courtesy of FORD MOTOR CO.
  69. Install the generator mounting bracket and bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 67: Installing Bolts And Generator Mounting Bracket
      G04584007Courtesy of FORD MOTOR CO.
  70. Connect the generator electrical connector.
    Fig 68: Connecting Generator Electrical Connector
    G04584008Courtesy of FORD MOTOR CO.
  71. Connect the electrical connector to the EGR vacuum regulator solenoid.
    Fig 69: Connecting Electrical Connector To EGR Vacuum Regulator Solenoid
    G04584009Courtesy of FORD MOTOR CO.
  72. Install the generator wiring harness anchor to the LH front stud.
    Fig 70: Installing Generator Wiring Harness Anchor To LH Front Stud
    G04584010Courtesy of FORD MOTOR CO.
  73. Connect the crankcase ventilation tube.
    Fig 71: Connecting Crankcase Ventilation Tube
    G04584011Courtesy of FORD MOTOR CO.
  74. Install the intake manifold shield and bolts.
    • Tighten to 12 Nm (9 lb-ft).
      Fig 72: Installing Bolts And Intake Manifold Shield
      G04584012Courtesy of FORD MOTOR CO.
  75. Connect the 8 fuel injector electrical connectors.
    Fig 73: Disconnecting Fuel Injector Electrical Connectors
    G04584013Courtesy of FORD MOTOR CO.
  76. Connect the 8 ignition coil electrical connectors.
    Fig 74: Connecting Fuel Injector Electrical Connectors
    G04584014Courtesy of FORD MOTOR CO.
  77. Connect the camshaft position (CMP) sensor electrical connector.
    Fig 75: Connecting Camshaft Position (CMP) Sensor Electrical Connector
    G04584015Courtesy of FORD MOTOR CO.
  78. Connect the radio interference capacitor electrical connector.
    Fig 76: Connecting Radio Interference Capacitor Electrical Connector
    G04584016Courtesy of FORD MOTOR CO.
  79. Connect the cylinder head temperature (CHT) sensor electrical connector.
    Fig 77: Disconnecting Cylinder Head Temperature (CHT) Sensor Electrical Connector
    G04584017Courtesy of FORD MOTOR CO.
  80. Connect the ground wire to the right rear fuel rail stud.
    Fig 78: Connecting Ground Wire To Right Rear Fuel Rail Stud
    G04584018Courtesy of FORD MOTOR CO.
  81. Install the battery cables and the bolt.
  82. Install the RH and LH lifting brackets.
    Fig 79: Installing RH And LH Lifting Brackets
    G04584019Courtesy of FORD MOTOR CO.
  83. Remove the engine from the engine stand.
    Fig 80: Removing Engine From Engine Stand
    G04584020Courtesy of FORD MOTOR CO.
  84. Install the engine/transmission spacer plate.
    Fig 81: Installing Engine/Transmission Spacer Plate
    G04584021Courtesy of FORD MOTOR CO.
  85. Position the flexplate and install the bolts in the sequence shown.
    • Tighten to 80 Nm (59 lb-ft).
      Fig 82: Installing Bolts In Sequence
      G04584022Courtesy of FORD MOTOR CO.
  86. Install the engine. For additional information, refer to ENGINE  in the Installation portion of this article.
    87. WARNING: If equipped with fire suppression system, repower the system. For important safety warnings and procedures, refer to FIRE SUPPRESSION SYSTEM .
  87. If equipped with fire suppression system, repower the system
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