Cylinder Heads
| Item | Specification |
|---|---|
| Motorcraft Premium Gold Engine Coolant VC-7-A or equivalent | WSE-M97B51-A1 |
| Super Premium SAE 5W-20 XO-5W20-QSP or equivalent | WSS-M2C153-H |
| Silicone Gasket and Sealant F7AZ-19554-EA (in Canada CXC-111-A) or equivalent | WSE-M4G323-A4 |
| Metal Surface Cleaner F4AZ-19A536-RA or equivalent | WSE-M5B392-A |
- To install individual components, carry out only the listed steps.CYLINDER HEAD INSTALLATION STEPS
Component Steps LH cylinder head 1-3, 15-65, 72-147 RH cylinder head 4-14, 23-59, 66-147 - Install the components in the order indicated in the following illustration and table.
- Install the components in the order indicated in the following illustration and table.
- Install the components in the order indicated in the following illustration and table.
- Install the components in the order indicated in the following illustration and table.
- Install the components in the order indicated in the following illustration and table.
- Install the components in the order indicated in the following illustration and table.
- Install the components in the order indicated in the following illustration and table.
- Install the components in the order indicated in the following illustration and table.
- Install the components in the order indicated in the following illustration and table.
- Install the components in the order indicated in the following illustration and table.
- Install the components in the order indicated in the following illustration and table.
- Install the components in the order indicated in the following illustration and table.
- Install the components in the order indicated in the following illustration and table.
- Install the components in the order indicated in the following illustration and table.
- Install the components in the order indicated in the following illustration and table.
- Install the components in the order indicated in the following illustration and table.
- Install the components in the order indicated in the following illustration and table.
- Install the components in the order indicated in the following illustration and table.
- Install the components in the order indicated in the following illustration and table.
- Install the components in the order indicated in the following illustration and table.
- Remove the engine from the engine stand.
- Install the engine. For additional information, Refer to ENGINE Installation.
ITEMS 1-6: RH AND LH CYLINDER HEAD INSTALLATION NOTE
- Lightly oil the new cylinder head bolts and allow to drain for a few minutes before installing.
- Position the cylinder heads.
- Install new gaskets.
- Install and tighten the RH head bolts in four stages in the sequence shown.
- Stage 1: Tighten bolts 1 through 10 to 20 Nm (15 lb-ft).
- Stage 2: Tighten bolts 1 through 10 to 35 Nm (26 lb-ft).
- Stage 3: Tighten bolts 1 through 10 to 45 Nm (33 lb-ft) and an additional 90 degrees.
- Stage 4: Tighten bolts 1 through 10 an additional 90 degrees.
- Install and tighten the bolts in two stages.
- Tighten to 20 Nm (15 lb-ft).
- Tighten an additional 90 degrees.
- Install and tighten the LH head bolts in four stages in the sequence shown.
- Stage 1: Tighten bolts 1 through 10 to 20 Nm (15 lb-ft).
- Stage 2: Tighten bolts 1 through 10 to 35 Nm (26 lb-ft).
- Stage 3: Tighten bolts 1 through 10 to 45 Nm (33 lb-ft) and an additional 90 degrees.
- Stage 4: Tighten bolts 1 through 10 an additional 90 degrees.
- Install and tighten the bolts in two stages.
- Tighten to 20 Nm (15 lb-ft).
- Tighten an additional 90 degrees.
- Position the camshafts on the camshaft journals.
- Install the RH camshaft bearing caps.
- Position the bearing caps.
- Install the bolts. Tighten the bolts in three stages in the sequence shown.
- Stage 1: Hand-tighten.
- Stage 2: Tighten to 6 Nm (53 lb-in).
- Stage 3: Tighten an additional 90 degrees.
- Install the LH camshaft bearing caps.
- Position the bearing caps.
- Install the bearing cap bolts. Tighten the bolts in three stages in the sequence shown.
- Stage 1: Hand-tighten.
- Stage 2: Tighten to 6 Nm (53 lb-in).
- Stage 3: Tighten an additional 90 degrees.
- Using a feeler gauge, confirm that the tappet and shim clearances are within specification. For additional information, refer to VALVE CLEARANCE CHECK .
- If tappet and shim clearances are not within specification, adjust the clearance. For additional information, refer to VALVE CLEARANCE ADJUSTMENT .
ITEMS 7-22: RH AND LH CAMSHAFT INSTALLATION NOTE
- Install the LH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.
- Using new bolts, install the LH VCT unit and exhaust camshaft sprocket bolts finger-tight.
- Remove the locking pin from the LH secondary timing chain tensioner.
ITEMS 24-30, : LH VARIABLE CAMSHAFT TIMING (VCT) UNIT, EXHAUST CAMSHAFT SPROCKET AND SECONDARY TIMING CHAIN INSTALLATION NOTE
- Install the RH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.
- Using new bolts, install the RH VCT unit and exhaust camshaft sprocket bolts finger-tight.
- Remove the locking pin from the RH secondary timing chain tensioner.
ITEMS 31-37: RH VARIABLE CAMSHAFT TIMING (VCT) UNIT, EXHAUST CAMSHAFT SPROCKET AND SECONDARY TIMING CHAIN INSTALLATION NOTE
- Reset the timing chain tensioners.
- Hold the lever toward the tensioner piston.
- Using finger pressure, compress the tensioner.
- Push the lever down and install a drill rod to lock the piston.
- Install the special tool on the LH head.
- Position the LH timing chain and crankshaft gear.
- Position the timing chain over the LH intake camshaft sprocket.
- Position the crankshaft gear in the timing chain.
- Install the LH timing chain guide.
- Install the LH timing chain tensioner arm.
- Install the LH timing chain tensioner.
- Install the timing chain tensioner and bolts.
- Remove the drill rod.
- Tighten the LH exhaust camshaft sprocket and variable camshaft timing (VCT) unit bolts in two stages:
- Stage 1: Tighten to 35 Nm (26 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
- Remove the special tool.
- Install the special tool on the right cylinder head.
- Position the RH timing chain over the RH intake camshaft sprocket and over the crankshaft gear.
- Install the RH timing chain guide.
- Install the RH timing chain tensioner arm.
- Install the RH timing chain tensioner.
- Install the timing chain tensioner and bolts.
- Remove the drill rod.
- Tighten the RH exhaust camshaft sprocket and VCT unit bolts in two stages:
- Stage 1: Tighten to 35 Nm (26 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
- Remove the special tool.
- Remove the special tool.
- Install the crankshaft position (CKP) sensor.
ITEMS 38-51: TIMING DRIVE COMPONENTS INSTALLATION NOTE
ITEMS 52 AND 55: VARIABLE CAM TIMING (VCT) BUSH CARRIER INSTALLATION NOTE
- Carefully insert the bush carrier into the VCT unit, compress ring seals with fingers as required. Fully seat the bush carrier by hand before fitting bolts.
ITEMS 58 AND 59: ENGINE FRONT COVER INSTALLATION NOTE
- Apply silicone gasket and sealant in eight places.
- Install the engine front cover.
- Install new gaskets.
- Position the engine front cover on the cylinder block.
- Loosely install the bolts.
- Tighten the bolts in two stages in the sequence shown.
- Stage 1: Tighten to 5 Nm (44 lb-in).
- Stage 2: Tighten to 10 Nm (89 lb-in).
ITEMS 61-62 AND 67-68: EXHAUST MANIFOLD INSTALLATION NOTE
- Install the exhaust manifold.
- Install a new gasket and the exhaust manifold.
- Tighten the eight nuts in the sequence shown.
ITEM 67: RH EXHAUST MANIFOLD INSTALLATION NOTE
- Install the EGR tube.
- Install a new EGR tube gasket.
- Install the EGR tube.
- Install the EGR tube nuts.
ITEMS 72-79: RH AND LH VALVE COVER INSTALLATION NOTE
- Inspect and install new gaskets as necessary.
- Apply four beads of silicone gasket and sealant as shown.
- Install the valve covers.
- Tighten the bolts in the sequence shown.
ITEMS 81-83: INTAKE MANIFOLD INSTALLATION NOTE
- Install new intake manifold gaskets.
- Install the intake manifold and tighten the bolts in the sequence shown.
- Install the radio interference capacitor and the nut.
ITEM 96: EGR SYSTEM MODULE INSTALLATION NOTE
- Connect the EGR system module-to-exhaust manifold tube from the EGR system module.
ITEM 103: ENGINE WIRING HARNESS INSTALLATION NOTE
- Install the wiring harness onto the front cover.
- Install the wiring harness onto the front cover.
- Connect the crankshaft position (CKP) sensor electrical connector.
- Install the exhaust gas oxygen sensor (HO2S) connectors onto the brackets.
- Connect the two pin-type retainers.
- Connect the variable cam timing (VCT) sensor electrical connector.
- Install the engine wiring harness retainer.
- Connect the fuel injector and radio interference capacitor electrical connectors.
- Connect the ignition coil electrical connectors.
- Connect the EGR system module electrical connector.
- Connect the generator electrical connector.
- Connect the engine wiring harness retainers to the RH engine appearance cover support bracket.
ITEMS 106 AND 107: ENGINE COVER SUPPORT BRACKET INSTALLATION NOTE
- Install the engine wiring harness retainers onto the engine cover support bracket.
- Install a new O-ring seal and the oil level indicator tube.
- Lubricate the new O-ring seal and engine mating surface with clean engine oil.
ITEM 109: OIL LEVEL INDICATOR TUBE INSTALLATION NOTE
ITEMS 122-125: RH AND LH COIL COVER INSTALLATION NOTE
- Lift up the wire harness and apply a 12.7 mm (0.5 in) bead of silicone sealer in the notch of the valve cover.
- Set the ignition coil harness in the bead of silicone sealer and apply enough additional sealer to surround the wire harness and notch.
- Install the coil cover.
- Connect the wiring harness retainers to the RH valve cover.
- Connect the wiring harness retainers to the RH valve cover.
ITEM 129: FRONT CRANKSHAFT SEAL INSTALLATION NOTE
- Using the special tool, install the front crankshaft seal.
ITEMS 130-132: CRANKSHAFT PULLEY INSTALLATION NOTE
- Apply silicone gasket and sealant to the crankshaft pulley keyway.
- Using the special tool, install the crankshaft pulley.
- Install the washer and a new bolt and tighten in two stages.
- Stage 1: Tighten to 80 Nm (59 lb-ft).
- Stage 2: Tighten an additional 80 degrees.
ITEM 134: COOLANT PUMP PULLEY BOLT INSTALLATION NOTE
- Do not tighten coolant pump pulley bolts until after the accessory drive belt has been installed.
ITEMS 144 AND 145: OIL FILTER AND SEAL INSTALLATION NOTE
- Install the oil filter until the seal makes contact. Tighten an additional 270 degrees.