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Home › Mercury › 2008 › Sable Base, AWD › Repair and Diagnosis › Engine Mechanical › Mechanical › Engine › Installation › Cylinder Head - LH

Cylinder Head - LH

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
CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.
  1. Install a new gasket, the LH cylinder head and 8 new bolts. Tighten in the sequence shown in 5 stages:
    • Stage 1: Tighten to 20 Nm (15 lb-ft).
    • Stage 2: Tighten to 35 Nm (26 lb-ft).
    • Stage 3: Tighten 90 degrees.
    • Stage 4: Tighten 90 degrees.
    • Stage 5: Tighten 90 degrees.
    2. Fig 1: Installing LH Cylinder Head Bolts In Sequence
    GF0029307Courtesy of FORD MOTOR CO.
  2. Install the bolt.
    • Tighten to 10 Nm (89 lb-in).
    3. Fig 2: Identifying M6 Bolt
    GF0029260Courtesy of FORD MOTOR CO.
    NOTE: The valve tappets must be installed in their original positions.
    NOTE: Coat the valve tappets with clean engine oil prior to installation.
  3. Install the valve tappets.
    4. Fig 3: Identifying Valve Tappets From Cylinder Head
    GF0029217Courtesy of FORD MOTOR CO.
  4. Install the LH secondary timing chain tensioner and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
    5. Fig 4: Locating LH Secondary Timing Chain Tensioner & Bolt
    GF0029259Courtesy of FORD MOTOR CO.
  5. Install the upper LH primary timing chain guide and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
    6. Fig 5: Locating Upper LH Primary Timing Chain Guide Bolts
    GF0029203Courtesy of FORD MOTOR CO.
  6. Using new gaskets, install the lower intake manifold and the 10 bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
    7. Fig 6: Installing Lower Intake Manifold Bolts In Sequence
    GF0029084Courtesy of FORD MOTOR CO.
  7. Using a new gasket and O-ring seal, install the thermostat housing and the 3 bolts.
    • Tighten to 10 Nm (89 lb-in).
    8. Fig 7: Locating Thermostat Housing-To-Lower Intake Manifold Bolts
    GF0031413Courtesy of FORD MOTOR CO.
    CAUTION: Use O-ring seals that are made of special fuel-resistant material. The use of ordinary O-rings may cause the fuel system to leak. Do not reuse the O-ring seals.
    NOTE: The upper and lower O-ring seals are not interchangeable.
  8. Install new fuel injector O-ring seals.
    • Remove the retaining clips and separate the fuel injectors from the fuel rail.
    • Remove and discard the O-ring seals.
    • Install new O-ring seals and lubricate with clean engine oil.
    • Install the fuel injectors and the retaining clips onto the fuel rail.
    9. Fig 8: Identifying Fuel Injector O-Ring Seals
    GF0029333Courtesy of FORD MOTOR CO.
  9. Install the fuel rail and injectors as an assembly and install the 4 bolts.
    • Tighten to 10 Nm (89 lb-in).
    10. Fig 9: Locating Fuel Rail And Injectors & Bolts
    GF0029240Courtesy of FORD MOTOR CO.
  10. Install the coolant bypass hose to the thermostat housing.
    11. Fig 10: Identifying Coolant By-Pass Hose
    GF0045683Courtesy of FORD MOTOR CO.
  11. Install the RH cylinder block drain plug or, if equipped, the block heater.
    • Tighten to 40 Nm (30 lb-ft).
    12. Fig 11: Locating RH Cylinder Block Drain Plug
    GF0029232Courtesy of FORD MOTOR CO.
  12. If equipped, install the block heater wiring harness onto the engine.
    • Connect the block heater electrical connector and install the heat shield.
    13. Fig 12: Identifying Block Heater Wiring Harness
    GF0029221Courtesy of FORD MOTOR CO.
  13. Using a new gasket, install the RH catalytic converter and 4 new nuts.
    • Tighten to 40 Nm (30 lb-ft).
    14. Fig 13: Identifying Nuts
    GF0045670Courtesy of FORD MOTOR CO.
  14. Install the LH cylinder block drain plug.
    • Tighten to 20 Nm (15 lb-ft) plus an additional 180 degrees.
    15. Fig 14: Locating LH Cylinder Block Drain Plug
    GF0029231Courtesy of FORD MOTOR CO.
  15. Install 6 new LH exhaust manifold studs.
    • Tighten to 12 Nm (9 lb-ft).
    16. Fig 15: Locating LH Exhaust Manifold Studs
    GF0029116Courtesy of FORD MOTOR CO.
    CAUTION: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.
  16. Using a new gasket, install the LH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown:
    • Stage 1: Tighten to 20 Nm (15 lb-ft).
    • Stage 2: Tighten to 20 Nm (15 lb-ft).
    17. Fig 16: Installing LH Exhaust Manifold Nuts In Sequence
    GF0029334Courtesy of FORD MOTOR CO.
  17. Install the LH exhaust manifold heat shield and the 3 bolts.
    • Tighten to 14 Nm (10 lb-ft).
    18. Fig 17: Locating LH Exhaust Manifold Heat Shield & Nuts
    GF0029256Courtesy of FORD MOTOR CO.
  18. Using a new gasket, install the LH catalytic converter and 4 new nuts (3 shown).
    • Tighten to 40 Nm (30 lb-ft).
    19. Fig 18: Locating LH Catalytic Converter Nuts
    GF0029230Courtesy of FORD MOTOR CO.
  19. Install the LH catalytic converter bracket bolts.
    • Tighten to 20 Nm (15 lb-ft).
    20. Fig 19: Locating LH Catalytic Converter Bracket Bolts
    GF0029229Courtesy of FORD MOTOR CO.
  20. Attach the engine oil pressure (EOP) switch wiring harness pin-type retainer.
    21. Fig 20: Identifying Wiring Harness Pin-Type Retainer
    GF0029251Courtesy of FORD MOTOR CO.
  21. Install the stud, generator and the nut and bolt.
    • Tighten the stud to 12 Nm (9 lb-ft).
    • Tighten nut and bolt to 48 Nm (35 lb-ft).
    22. Fig 21: Locating Generator, Bolts & Nuts
    GF0029250Courtesy of FORD MOTOR CO.
  22. Connect the generator electrical connector.
    23. Fig 22: Identifying Generator Electrical Connector
    GF0029248Courtesy of FORD MOTOR CO.
  23. Connect the generator B+ cable and install the nut.
    • Tighten to 6 Nm (53 lb-in).
    24. Fig 23: Identifying Generator B+ Cable & Nut
    GF0029247Courtesy of FORD MOTOR CO.
  24. Attach the pin-type wire harness retainer to the rear of LH cylinder head.
    25. Fig 24: Identifying Wiring Harness Retainer
    GF0045684Courtesy of FORD MOTOR CO.
  25. Connect the LH catalyst monitor sensor electrical connector.
    26. Fig 25: Identifying LH Catalyst Monitor Sensor Electrical Connector
    GF0041326Courtesy of FORD MOTOR CO.
  26. Connect the LH heated oxygen sensor (HO2S) electrical connector.
    27. Fig 26: Locating LH Heated Oxygen Sensor (HO2S) Electrical Connector
    GF0029254Courtesy of FORD MOTOR CO.
  27. Install LH camshaft position (CMP) sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).
    28. Fig 27: Locating LH CMP Sensor & Bolt
    GF0029258Courtesy of FORD MOTOR CO.
  28. Connect the LH CMP sensor electrical connector.
    29. Fig 28: Locating LH CMP Sensor Electrical Connector
    GF0029253Courtesy of FORD MOTOR CO.
  29. Connect the cylinder head temperature (CHT) sensor electrical connector.
    30. Fig 29: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector
    GF0029227Courtesy of FORD MOTOR CO.
  30. Connect the 6 fuel injector electrical connectors (3 shown).
    31. Fig 30: Locating Fuel Injector Electrical Connectors
    GF0029226Courtesy of FORD MOTOR CO.
  31. Install the LH camshafts. For additional information, refer to Camshaft .
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