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Cylinder Head: Assembly

All cylinder heads 

  1. Install the valve.
    GFD344894Courtesy of FORD MOTOR COMPANY
  2. NOTE: Lubricate the valve stem seal with clean engine oil prior to installation.

    Using the special tool, install the valve stem seal. Use Special Service Tool: 303-470 (T94P-6510-CH) Installer, Valve Stem Oil Seal.

    Material: Castrol® EDGE® Supercar 5W-50 (WSS-M2C931-C)

    GFD344895Courtesy of FORD MOTOR COMPANY
  3. Using the special tools, install the valve spring, valve spring retainer and the valve collet. Use Special Service Tool: 303-1418 Compressor, Valve Spring, 303-300 (T87C-6565-A) Set, Valve Spring Compressor, 303-350 (T89P-6565-A) Compressor, Valve Spring, 303-1249 Valve Spring Compressor.
    GFD344891Courtesy of FORD MOTOR COMPANY
  4. Repeat the previous 3 steps for each valve.
  5. Install the spark plugs.

    Torque: 133 lb.in (15 Nm)

    GFD344890Courtesy of FORD MOTOR COMPANY

    RH cylinder head 

  6. NOTE: Do not lubricate the new lower Teflon® fuel injector seals.

    1. Install the Arbor on the fuel injector tips. Use Special Service Tool: 310-207 Installer, Fuel Injector Seal Assembly.
    2. NOTE: Once the Teflon® seal is installed on the Teflon® Seal Guide, it should immediately be installed onto the fuel injector to avoid excessive expansion of the Teflon® seal.
      NOTE: Make sure that new lower fuel injector Teflon® seals are installed.

      Install the new Teflon® seals onto the Arbor, using the Pusher Tool (part of the Fuel Injector Seal Installer), slide the Teflon® seals along the Arbor.

    3. Using the Pusher Tool, slide the Teflon® seals off of the Teflon® Seal Guide and into the groove on the fuel injectors. Use Special Service Tool: 310-207 Installer, Fuel Injector Seal Assembly.

    GFD344896Courtesy of FORD MOTOR COMPANY
  7. NOTE: Install the fuel injectors into the cylinder head within 15 minutes of sizing the seals due to Teflon® seal expansion.
    NOTE: Make sure the Teflon® seal is fully seated in the groove on the fuel injector before sizing the Teflon® seal.

    1. Some Teflon® seal massaging with your fingers before the Teflon® seal sizer tool is installed will aid in installing the Teflon® seal sizer tool.
    2. Position the Teflon® Seal Sizer tool with the larger opening towards the Teflon® seal. Push while turning the Teflon® Seal Sizer tool 180 degrees. Use Special Service Tool: 303-1567 Sizer, Teflon Seal.
    3. Once the Teflon® Seal Sizer tool is installed, check and make sure the Teflon® seal is in the sizing portion of the Teflon® Seal Sizer tool.
    4. After one minute, turn the Teflon® seal sizer tool back 180 degrees and remove.

    GFD344897Courtesy of FORD MOTOR COMPANY
    1. NOTE: The large diameter step of the backup ring must go up towards the new O-ring seal. Improperly installed backup rings may cause the fuel system to leak.

      Install the fuel injector backup ring.

    2. NOTE: Use fuel injector O-ring seals that are made of special fuel-resistant material. The use of ordinary O-ring seals may cause the fuel system to leak. Do not reuse the O-ring seals.
      NOTE: Do not lubricate the new lower Teflon® fuel injector seals.

      Install the new fuel injector O-ring seals. Lubricate the new fuel injector O-ring seals with clean engine oil.

      Material: Castrol® EDGE® Supercar 5W-50 (WSS-M2C931-C)

    3. Install the new the fuel injector retaining clip.
    GFD344898Courtesy of FORD MOTOR COMPANY
  9. NOTE: The anti-rotation finger of the fuel injector must slip into the groove of the fuel rail cup.

    Install the fuel injectors into the fuel rail.

    GFD344899Courtesy of FORD MOTOR COMPANY
  10. NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
    NOTE: Make sure that new fuel rail mounting bolts are installed.
    NOTE: Push down on the fuel rail above the injectors.

    • Install the fuel injectors and direct injection fuel rail assembly into the cylinder head. Tighten the bolts in sequence shown in 2 stages.

      Torque: Stage 1: 89 lb.in (10 Nm) | Stage 2: 45°

    • Connect the fuel injector electrical connectors.

    Fig 1: RH Fuel Rail Assembly Bolts Tightening Sequence
    GFD344900Courtesy of FORD MOTOR COMPANY
  11. NOTE: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals.
    NOTE: The upper and lower fuel injector O-ring seals are similar in appearance, but are not interchangeable.
    NOTE: Make sure that new fuel injector O-ring seals are installed.

    Install the new fuel injector O-ring seals and the fuel injector retaining clips onto the fuel injectors. Lubricate the new fuel injector O-ring seals with clean engine oil.

    Material: Castrol® EDGE® Supercar 5W-50 (WSS-M2C931-C)

    GFD344901Courtesy of FORD MOTOR COMPANY
  12. NOTE: The anti-rotation finger of the fuel injector must slip into the groove of the fuel rail cup.

    Install the fuel injectors into the fuel rail.

    GFD344902Courtesy of FORD MOTOR COMPANY
  13. NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
    NOTE: Make sure that new fuel rail mounting bolts are installed.
    NOTE: Push down on the fuel rail above the injectors.

    • Install the fuel injectors and port injection fuel rail assembly into the cylinder head and tighten the bolts.

      Torque: 89 lb.in (10 Nm)

    • Connect the fuel injector electrical connectors.

    GFD344903Courtesy of FORD MOTOR COMPANY
  14. NOTE: Install short end of stud into cylinder head assembly.

    • Loosely install the new studs into the cylinder head.

    • Tighten the studs in sequence shown.

      Torque: 159 lb.in (18 Nm)

    • Install the new exhaust manifold gasket.

    Fig 2: RH Cylinder Head Studs Tightening Sequence
    GFD344904Courtesy of FORD MOTOR COMPANY
  15. Install the exhaust manifold and the new nuts. Tighten the nuts in sequence shown in 2 stages.

    Torque: Stage 1: 142 lb.in (16 Nm) | Stage 2: 16 lb.ft (22 Nm) | Stage 3: 16 lb.ft (22 Nm)

    Fig 3: RH Exhaust Manifold Nuts Tightening Sequence
    GFD344905Courtesy of FORD MOTOR COMPANY
  16. NOTE: Apply Bostik Never-Seez Regular Grade (nickel free) Anti-Seize and Lubricating Compound to the bolts.

    Install the bottom exhaust manifold heat shield and the bolts.

    Material: Bostik Never-Seez Regular Grade (nickel free) Anti-Seize and Lubricating Compound

    Torque: 97 lb.in (11 Nm)

    GFD344906Courtesy of FORD MOTOR COMPANY
  17. Install the new CHT sensor.

    Torque: 97 lb.in (11 Nm)

    GFD344907Courtesy of FORD MOTOR COMPANY
  18. Install Special Service Tool: 303-1654 Lift Eyes.

    Torque: 18 lb.ft (25 Nm)

    GFD344877Courtesy of FORD MOTOR COMPANY

    LH cylinder head 

  19. NOTE: Do not lubricate the new lower Teflon® fuel injector seals.

    1. Install the Arbor on the fuel injector tips Use Special Service Tool: 310-207 Installer, Fuel Injector Seal Assembly.
    2. NOTE: Once the Teflon® seal is installed on the Teflon® Seal Guide, it should immediately be installed onto the fuel injector to avoid excessive expansion of the Teflon® seal.
      NOTE: Make sure that new lower fuel injector Teflon® seals are installed.

      Install the new Teflon® seals onto the Arbor, using the Pusher Tool (part of the Fuel Injector Seal Installer), slide the Teflon® seals along the Arbor.

    3. Using the Pusher Tool, slide the Teflon® seals off of the Teflon® Seal Guide and into the groove on the fuel injectors. Use Special Service Tool: 310-207 Installer, Fuel Injector Seal Assembly.

    GFD344896Courtesy of FORD MOTOR COMPANY
  20. NOTE: Install the fuel injectors into the cylinder head within 15 minutes of sizing the seals due to Teflon® seal expansion.
    NOTE: Make sure the Teflon® seal is fully seated in the groove on the fuel injector before sizing the Teflon® seal.

    1. Some Teflon® seal massaging with your fingers before the Teflon® seal sizer tool is installed will aid in installing the Teflon® seal sizer tool.
    2. Position the Teflon® Seal Sizer tool with the larger opening towards the Teflon® seal. Push while turning the Teflon® Seal Sizer tool 180 degrees. Use Special Service Tool: 303-1567 Sizer, Teflon Seal.
    3. Once the Teflon® Seal Sizer tool is installed, check and make sure the Teflon® seal is in the sizing portion of the Teflon® Seal Sizer tool.
    4. After one minute, turn the Teflon® seal sizer tool back 180 degrees and remove.

    GFD344897Courtesy of FORD MOTOR COMPANY
    1. NOTE: The large diameter step of the backup ring must go up towards the new O-ring seal. Improperly installed backup rings may cause the fuel system to leak.

      Install the fuel injector backup ring.

    2. NOTE: Use fuel injector O-ring seals that are made of special fuel-resistant material. The use of ordinary O-ring seals may cause the fuel system to leak. Do not reuse the O-ring seals.
      NOTE: Do not lubricate the new lower Teflon® fuel injector seals.

      Install the new fuel injector O-ring seals. Lubricate the new fuel injector O-ring seals with clean engine oil.

      Material: Castrol® EDGE® Supercar 5W-50 (WSS-M2C931-C)

    3. Install the new the fuel injector retaining clip.
    GFD344898Courtesy of FORD MOTOR COMPANY
  22. NOTE: The anti-rotation finger of the fuel injector must slip into the groove of the fuel rail cup.

    Install the fuel injectors into the fuel rail.

    GFD344908Courtesy of FORD MOTOR COMPANY
  23. NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
    NOTE: Make sure that new fuel rail mounting bolts are installed.
    NOTE: Push down on the fuel rail above the injectors.

    • Install the fuel injectors and direct injection fuel rail assembly into the cylinder head. Tighten the bolts in sequence shown in 2 stages.

      Torque: Stage 1: 89 lb.in (10 Nm) | Stage 2: 45°

    • Connect the fuel injector electrical connectors.

    Fig 4: LH Fuel Rail Assembly Bolts Tightening Sequence
    GFD344909Courtesy of FORD MOTOR COMPANY
  24. NOTE: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals.
    NOTE: The upper and lower fuel injector O-ring seals are similar in appearance, but are not interchangeable.
    NOTE: Make sure that new fuel injector O-ring seals are installed.

    Install the new fuel injector O-ring seals and the fuel injector retaining clips onto the fuel injectors. Lubricate the new fuel injector O-ring seals with clean engine oil.

    Material: Castrol® EDGE® Supercar 5W-50 (WSS-M2C931-C)

    GFD344901Courtesy of FORD MOTOR COMPANY
  25. NOTE: The anti-rotation finger of the fuel injector must slip into the groove of the fuel rail cup.

    Install the fuel injectors into the fuel rail.

    GFD344910Courtesy of FORD MOTOR COMPANY
  26. NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
    NOTE: Make sure that new fuel rail mounting bolts are installed.
    NOTE: Push down on the fuel rail above the injectors.

    • Install the fuel injectors and port injection fuel rail assembly into the cylinder head and tighten the bolts.

      Torque: 89 lb.in (10 Nm)

    • Connect the fuel injector electrical connectors.

    GFD344911Courtesy of FORD MOTOR COMPANY
  27. NOTE: Install short end of stud into cylinder head assembly.

    • Loosely install the new studs into the cylinder head.

    • Tighten the studs in sequence shown.

      Torque: 159 lb.in (18 Nm)

    • Install the new exhaust manifold gasket.

    Fig 5: LH Cylinder Head Studs Tightening Sequence
    GFD344912Courtesy of FORD MOTOR COMPANY
  28. Install the exhaust manifold and the new nuts. Tighten the nuts in sequence shown in 2 stages.

    Torque: Stage 1: 142 lb.in (16 Nm) | Stage 2: 16 lb.ft (22 Nm) | Stage 3: 16 lb.ft (22 Nm)

    Fig 6: LH Exhaust Manifold Nuts Tightening Sequence
    GFD344913Courtesy of FORD MOTOR COMPANY
  29. NOTE: Apply Bostik Never-Seez Regular Grade (nickel free) Anti-Seize and Lubricating Compound to the bolts.

    Install the bottom exhaust manifold heat shield and the bolts.

    Material: Bostik Never-Seez Regular Grade (nickel free) Anti-Seize and Lubricating Compound

    Torque: 97 lb.in (11 Nm)

    GFD344914Courtesy of FORD MOTOR COMPANY
  30. Install Special Service Tool: 303-1654 Lift Eyes.

    Torque: 18 lb.ft (25 Nm)

GFD344862Courtesy of FORD MOTOR COMPANY
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