Cylinder Head
Special Tools
| Illustration | Tool Name | Tool Number |
|---|---|---|
| Remover/Installer, Cylinder Head | 303-572 (T97T-6000-A) | |
| Compressor, Valve Spring | 303-1039 | |
| Locking Tool, Camshaft Phaser Sprocket | 303-1046 | |
| Installer, Crankshaft Vibration Damper | 303-102 (T74P-6316-B) | |
| Installer, Crankshaft Front Seal | 303-635 | |
| Installer, Front Cover Seal | 303-335 (T88T-6701-A) | |
| Modular Engine Lift Bracket | 303-F047 (014-00073) or equivalent |
Material
| Item | Specification |
|---|---|
| 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 |
| Motorcraft Premium Gold Engine Coolant with Bittering Agent (US only) VC-7-B (US); CVC-7-A (Canada); or equivalent (yellow color) |
WSS-M97B51-A1 |
| Silicone Gasket and Sealant TA-30 |
WSE-M4G323-A4 |
| Motorcraft Metal Surface Prep ZC-31 |
- |
| Silicone Gasket Remover ZC-30 |
- |
| Hydraulic Chain Tensioner Retaining Clip 1L3Z-6P250-AA |
- |
All cylinder heads
- Using the special tools, position the cylinder head gaskets and cylinder heads over the dowels and install the cylinder head bolts loosely.
- Tighten the bolts in 3 stages, 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.
- Remove the special tool from the LH cylinder head.
- Install the hydraulic lash adjusters into the LH cylinder head.
- Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.
- Install 8 new exhaust manifold studs.
- Tighten to 12 Nm (9 lb-ft).
- Position a new gasket, the LH exhaust manifold and tighten the 8 new nuts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).
- Position the exhaust manifold heat shield and install the 3 bolts.
- Remove the special tool from the RH cylinder head.
- Install the hydraulic lash adjusters into the RH cylinder head.
- Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.
- Install 8 new exhaust manifold studs.
- Tighten to 12 Nm (9 lb-ft).
- Position a new gasket, the RH exhaust manifold and tighten the 8 new nuts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).
- Install the coolant tube and the stud bolt.
- Tighten to 10 Nm (89 lb-in).
- Install the LH and RH camshafts.
- Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.
- 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 bolts loosely.
- Tighten to 10 Nm (89 lb-in) in the sequence shown.
- Install the VCT phaser sprockets and new VCT phaser sprocket bolts finger tight.
- Using the special tool, tighten the LH and RH VCT phaser sprocket bolts in 2 stages.
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
- Compress the tensioner plunger, using a vise.
- Install a retaining clip on the tensioner to hold the plunger in during installation.
- Remove the tensioner from the vise.
- 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.
- Position the crankshaft keyway at the 11 o'clock position.
- Install the crankshaft sprocket, making sure the flange faces forward.
- Install the 4 bolts and the LH and RH timing chain guides.
- Tighten to 10 Nm (89 lb-in).
- 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.
- Position the timing chain on the VCT phaser sprocket with the timing mark positioned between the 2 copper (marked) chain links.
- Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner and bolts.
- Tighten to 25 Nm (18 lb-ft).
- Remove the retaining clip from the LH timing chain tensioner.
- 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.
- Position the RH timing chain on the VCT phaser sprocket with the timing mark positioned between the 2 copper (marked) chain links.
- Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and bolts.
- Tighten to 25 Nm (18 lb-ft).
- Remove the retaining clip from the RH timing chain tensioner.
- As a post-check, verify correct alignment of all timing marks.
- Install the crankshaft sensor ring on the crankshaft.
- Using the special tool, install all of the camshaft roller followers.
- Lubricate the camshaft roller followers with clean engine oil prior to installation.
- 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.
- 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.
- 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 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 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 W706605 Bolt, Hex Head Pilot, M8 x 1.25 x 56 - Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
- Install the 4 front oil pan bolts in the sequence shown in 2 stages.
- Stage 1: Tighten to 20 Nm (15 lb-ft).
- Stage 2: Tighten an additional 60 degrees.
- Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
- Position the RH valve cover and gasket on the cylinder head and tighten the bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
- Position the RH valve cover and gasket on the cylinder head and tighten the bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
- Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
- Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
- Position the LH valve cover and gasket on the cylinder head and tighten the bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
- Position the LH valve cover and gasket on the cylinder head and tighten the bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).
- Install the oil level indicator tube and the bolt.
- Install a new O-ring seal and lubricate the O-ring seal with clean engine oil prior to installation.
- Tighten to 10 Nm (89 lb-in).
- Position the RH engine support insulator and install the 3 bolts.
- Tighten to 63 Nm (46 lb-ft).
- Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
- Using the special tools, install a new crankshaft front seal into the engine front cover.
- Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
- Using the special tool, install the crankshaft pulley.
- 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.
- Install the LH camshaft position (CMP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
- Install the RH CMP sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
- Position the crankshaft position (CKP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
- Position the accessory drive belt tensioner and install the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
- Install the 3 accessory drive belt idler pulleys, the coolant pump pulley and the 7 bolts.
- Tighten to 25 Nm (18 lb-ft).
- Position the electrical harness on the engine assembly and connect the engine wiring harness retainers to the valve cover studs.
- Install the 8 ignition coils and the 8 bolts.
- Tighten to 6 Nm (53 lb-in).
- Install the LH radio ignition interference capacitor and the nut.
- Tighten to 25 Nm (18 lb-ft).
- Connect the cylinder head temperature (CHT) sensor electrical connector.
- Connect the 4 RH ignition coil electrical connectors.
- Connect the electrical connector retainer to the coolant tube.
- Connect the 2 engine wiring harness retainers from the RH valve cover studs.
- Connect the RH and LH VCT solenoid electrical connectors.
- Install the RH radio ignition interference capacitor and the stud bolt.
- Tighten to 25 Nm (18 lb-ft).
- Connect the RH and LH CMP sensor electrical connectors.
- Using a suitable floor crane, remove the engine from the engine stand.
- Install the flexplate and the 8 bolts in the sequence shown.
- Tighten to 80 Nm (59 lb-ft).
- Install the engine. For additional information, refer to Engine .
CAUTION:
Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore.
CAUTION:
The use of sealing aids (aviation cement, copper spray, and glue) is not permitted. The gasket must be installed dry.
CAUTION:
The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.
NOTE:
Do not turn the crankshaft until instructed to do so.
NOTE:
LH shown, RH similar.
NOTE:
RH shown, LH similar.
LH cylinder head
RH cylinder head
All cylinder heads
NOTE:
LH shown, RH similar.
CAUTION:
Damage to the variable camshaft timing (VCT) phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.
NOTE:
LH shown, RH similar.
CAUTION:
Damage to the VCT phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.
CAUTION:
Only use hand tools to remove the VCT phaser sprocket assembly or damage may occur to the camshaft or VCT phaser sprocket.
NOTE:
LH shown, RH similar.
CAUTION:
Timing chain procedures must be followed exactly or damage to valves and pistons will result.
CAUTION:
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.
NOTE:
Make sure the upper half of the timing chain is below the tensioner arm dowel.
NOTE:
The LH timing chain tensioner arm has a bump near the dowel hole for identification.
NOTE:
The camshaft phaser and sprocket will be stamped with one of the illustrated timing marks for the RH camshaft.
CAUTION:
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 with silicone gasket remover and metal surface prep. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Follow the directions on the packaging. Failure to follow this procedure can 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 Silicone Gasket And Sealant Along Cylinder Head-To-Cylinder Block Surface And Oil Pan-To-Cylinder Block Surface
CAUTION:
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.
NOTE:
If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with 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 can cause future oil leakage.
Fig 37: Applying Bead Of Silicone Gasket And Sealant In 2 Places Where Engine Front Cover Meets Cylinder Head
Early build vehicles
CAUTION:
When installing the valve cover, make sure to avoid damaging the VCT solenoid.
Late build vehicles
CAUTION:
When installing the valve cover, make sure to avoid damaging the VCT solenoid.
All vehicles
CAUTION:
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.
NOTE:
If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with 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 can cause future oil leakage.
Fig 40: Applying Bead Of Silicone Gasket And Sealant In 2 Places Where Engine Front Cover Meets Cylinder Head
Early build vehicles
CAUTION:
When installing the valve cover, make sure to avoid damaging the VCT solenoid.
Late build vehicles
CAUTION:
When installing the valve cover, make sure to avoid damaging the VCT solenoid.
All vehicles
NOTE:
If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with 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 can cause future oil leakage.
NOTE:
Lubricate the O-ring seal with clean engine oil prior to installation.
NOTE:
Lubricate the O-ring seal with clean engine oil prior to installation.
NOTE:
Lubricate the O-ring seal with clean engine oil prior to installation.
NOTE:
LH shown, RH similar.
NOTE:
RH shown, LH similar.
NOTE:
RH shown, LH similar.