Cylinder Head RH: Installation

LHD AWD/LHD RWD 

1. Inspect the turbochargers and engine air intake system components and clean, if necessary.
2. Install a new cylinder head gasket.

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3. • Install the cylinder head.
   • Install new cylinder head bolts.

     Torque: Stage 1: 177 lb. in (20 Nm) Stage 2: Loosen: 2 turn(s) Stage 3: 37 lb. ft (50 Nm) Stage 4: 180°

   Fig 1: RH Cylinder Head Tightening Sequence

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4. Install a new fuel rail-to-fuel rail high-pressure fuel tube and finger tighten the flare nuts.
   • Final tighten the flare nuts.

     Torque: Stage 1: 62 lb. in (7 Nm) Stage 2: 89 lb. in (10 Nm) Stage 3: 25°

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5. Install the RH cylinder head to coolant outlet connector hose assembly. Refer to: Cylinder Head to Coolant Outlet Connector Hose Assembly .
6. NOTE: Do not install the camshaft roller followers at this time. The roller followers will be installed later in the procedure. If the roller followers are installed prior to the camshafts, the camshaft caps can become distorted during the camshaft tightening process and result in upper end engine noise or severe damage to the engine.
   NOTE: If the original components are to be reinstalled, they must be installed in their original locations.
   1. Lubricate the hydraulic lash adjusters with clean engine oil.
   2. Install the hydraulic lash adjusters.

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7. • Lubricate the camshafts with clean engine oil.
   • Install the intake and exhaust camshafts in the neutral position. Align the D-slots as shown in the illustration.

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8. Apply a 1 mm bead of sealant to the rear camshaft cap mounting surface of the cylinder head.

   Material: Flange Sealant / CU7Z-19B508-A (WSS-M2G348-A11)

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9. Install the camshaft bearing caps and the bolts. Do not tighten at this time.

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10. Install the front camshaft bearing mega cap and the bolts. Do not tighten at this time.

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11. Tighten the bolts.

    Torque: 89 lb. in (10 Nm)

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12. Install the RH VCT units. Refer to: Variable Camshaft Timing (VCT) Unit .
13. Install new engine front cover gaskets.

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14. NOTE: Lubricate the new oil gallery seal with clean engine oil.

    Lubricate and install a new oil gallery seal (6G068).

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15. NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
    NOTE: The engine front cover must be installed within 10 minutes of applying the sealer and the bolts must be installed and tightened to 2-5 Nm (18-44 lb-in) within 15 of applying the sealer. Final tightening of the bolts must be completed within 60 minutes of applying the sealer. Failure to follow this procedure can cause future oil leakage.

    Apply 9 mm (0. 35 in) beads of Motorcraft® High Performance Engine RTV Silicone 10 mm (0. 40 in) in length to the cylinder block skirt-to-cylinder block joints and the cylinder head-to-cylinder block joints as indicated.

    Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

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16. NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
    NOTE: The engine front cover must be installed within 10 minutes of applying the sealer and the bolts must be installed and tightened to 2-5 Nm (18-44 lb-in) within 15 of applying the sealer. Final tightening of the bolts must be completed within 60 minutes of applying the sealer. Failure to follow this procedure can cause future oil leakage.
    1. Apply a 4. 5 mm (0. 18 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover sealing surfaces of the inner bolt bosses.

       Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

    2. Apply a 4. 5 mm (0. 18 in) bead of Motorcraft® High Performance Engine RTV Silicone to the chamfer of the engine front cover sealing surfaces.

       Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

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17. Install the engine front cover and the fasteners.

    Torque: Stage 1: Tighten bolts 1 through 11 to: 18 lb. ft (24 Nm) Stage 2: Tighten bolts 12 through 13 to: 35 lb. ft (48 Nm) Stage 3: Tighten bolts 14 through 20 to: 18 lb. ft (24 Nm)

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18. Attach the wiring harness retainer.

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19. Position the A/C compressor.
    • Install the bolts.

      Torque: 18 lb. ft (25 Nm)

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20. Connect the A/C compressor electrical connectors.
    • Attach the wiring harness retainer.

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21. NOTE: A new turbocharger oil supply filter must be installed. Failure to follow these instructions can result in turbocharger damage.

    Install the new turbocharger oil supply tube O-ring seals and the new turbocharger oil supply tube oil filter. Lubricate the new turbocharger oil supply tube O-ring seals with clean engine oil.

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22. NOTE: Use brake cleaner and a nylon brush to clean. Do not use a metal brush, damage to sealing area will result in leaks.
    • Carefully use a nylon brush to remove the old O-ring residue and use brake cleaner to rinse the O-ring residue out of the turbocharger tube to turbocharger O-ring bore and the turbocharger tube to engine O-ring bore. Inspect the area for deep scratches and gouges. Do not use a metal brush, damage to sealing area will result in leaks. Install new components if needed.
    1. Connect the turbocharger oil supply tube to the turbocharger, then install and tighten the turbocharger oil supply tube bolt.

       Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

       Torque: 89 lb. in (10 Nm)

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23. • NOTE: Use brake cleaner and a nylon brush to clean. Do not use a metal brush, damage to sealing area will result in leaks.

      Carefully use a nylon brush to remove the old O-ring residue and use brake cleaner to rinse the O-ring residue out of the turbocharger tube to engine O-ring bores for both the oil and coolant tubes. Inspect the area for deep scratches and gouges. Do not use a metal brush, damage to sealing area will result in leaks. Install new components if needed.

    1. Install the turbocharger, the new gasket, the bolt and the stud. Install the turbocharger oil supply tube to the engine while installing the turbocharger.

       Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

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24. 1. Install the front turbocharger stud.
    2. Tighten the turbocharger studs.

       Torque: 106 lb. in (12 Nm)

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25. Loosely install the turbocharger nuts.

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26. Tighten the turbocharger bolt.

    Torque: 44 lb. ft (60 Nm)

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27. 1. Tighten the turbocharger nut.

       Torque: 27 lb. ft (37 Nm)

    2. Tighten the turbocharger nut.

       Torque: 44 lb. ft (60 Nm)

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28. Re-tighten the turbocharger bolt.

    Torque: 44 lb. ft (60 Nm)

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29. 1. Re-tighten the turbocharger nut

       Torque: 27 lb. ft (37 Nm)

    2. Re-tighten the turbocharger nuts.

       Torque: 44 lb. ft (60 Nm)

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30. Install a new outer turbocharger coolant supply tube O-ring seal. Lubricate the O-ring seal and the rubber gasket with clean engine coolant.

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31. NOTE: Use brake cleaner and a nylon brush to clean. Do not use a metal brush, damage to sealing area will result in leaks.
    • Carefully use a nylon brush to remove the old O-ring residue and use brake cleaner to rinse the O-ring residue out of the turbocharger tube to engine O-ring bore. Inspect the area for deep scratches and gouges. Install new components if needed.
    1. Install the outer turbocharger coolant supply tube, then install and tighten the bolt.

       Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

       Torque: 89 lb. in (10 Nm)

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32. Connect the turbocharger wastegate control hose and clamp. Use the General Equipment: Hose Clamp Remover/Installer

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33. NOTE: Do not use a metal brush, damage to sealing area will result in leaks.
    • Carefully use a nylon brush to remove the old O-ring residue and use brake cleaner to rinse the O-ring residue out of the turbocharger tube to turbocharger O-ring bore and the turbocharger tube to engine O-ring bore. Inspect the area for deep scratches and gouges. Install new components if needed.
    1. Install the turbocharger oil supply tube, then install and tighten the oil supply tube bolt.

       Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

       Torque: 89 lb. in (10 Nm)

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34. Install a new turbocharger coolant return tube O-ring seal. Lubricate the new O-ring seal with clean engine coolant.

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35. Install and connect the turbocharger coolant return tube and clamp. Use the General Equipment: Hose Clamp Remover/Installer

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36. NOTE: Do not use a metal brush, damage to sealing area will result in leaks.
    • Carefully use a nylon brush to remove the old O-ring residue and use brake cleaner to rinse the O-ring residue out of the turbocharger O-ring bore. Inspect the area for deep scratches and gouges. Install new components if needed.

      Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

    1. Connect the turbocharger coolant return tube to the turbocharger, then install and tighten the bolt.

       Torque: 89 lb. in (10 Nm)

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37. Install the turbocharger heat shield and the bolts.

    Torque: 89 lb. in (10 Nm)

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38. Remove the engine front cover bolts.

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39. Using two M8 x 1. 25 x 105 mm bolts and two washers, install the special tools to the engine. Install Special Service Tool: 303-050 (T70P-6000) Lifting Bracket, Engine.

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40. Install Special Service Tool: 303-F070 Support Bar, Engine.

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41. Support the front and rear of the subframe with adjustable jack stands.

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42. • Remove the rear subframe bolts.
    • Discard the bolts.

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43. • Remove the middle subframe bolts.
    • Discard the bolts.

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44. • Remove the front subframe bolts.
    • Discard the bolts.

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45. With the aid of an assistant, lower the front jack stand 127 mm (5. 0 in) and the rear jack stand 152. 4 mm (6. 0 in) evenly or until engine mount stud clears the subframe.

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46. NOTE: Early build shown, late build similar.
    • Remove the bolts and the LH engine mount.
    • Discard the bolts.

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    LHD AWD 

47. Install a new seal and lubricate.

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48. Install the front axle disconnect actuator and the bolts.

    Torque: 26 lb. ft (35 Nm)

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49. Connect the front axle disconnect actuator electrical connector and vent hose.

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    LHD AWD/LHD RWD 

50. Install the new turbocharger oil return tube-to-engine block gasket.

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51. Install a new turbocharger oil return tube O-ring seal, then lubricate with clean engine oil.

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52. NOTE: Do not use a metal brush, damage to sealing area will result in leaks.
    • Carefully use a nylon brush to remove the old O-ring residue and use brake cleaner to rinse the O-ring residue out of the turbocharger O-ring bore. Inspect the area for deep scratches and gouges.
    1. Install the turbocharger oil return tube, then install and tighten the turbocharger oil return tube bolts.

       Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

       Torque: 89 lb. in (10 Nm)

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53. Install the wire harness bracket, then install and tighten the bolt.

    Torque: 106 lb. in (12 Nm)

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54. NOTE: Early build shown, late build similar.

    Remove and discard the nuts and bolts.

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55. NOTE: Early build shown, late build similar.
    • Remove the studs and the RH engine mount.
    • Discard the studs.

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    LHD RWD 

56. Remove the bolt and the engine mount spacer.

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    LHD AWD/LHD RWD 

57. Install a new turbocharger coolant supply tube O-ring seals. Lubricate the new O-ring seal with clean engine coolant.

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58. • NOTE: Use brake cleaner and a nylon brush to clean. Do not use a metal brush, damage to sealing area will result in leaks.

      Carefully use a nylon brush to remove the old O-ring residue and use brake cleaner to rinse the O-ring residue out of the turbocharger tube to turbocharger O-ring bore. Inspect the area for deep scratches and gouges. Install new components if needed.

    • Install the turbocharger coolant supply tube to the turbocharger, then install and tighten the turbocharger coolant supply tube bolt.

      Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

      Torque: 89 lb. in (10 Nm)

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59. Install the new turbocharger oil supply tube O-ring seals and the new turbocharger oil supply tube oil filter. Lubricate the new turbocharger oil supply tube O-ring seals with clean engine oil.

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60. NOTE: Use brake cleaner and a nylon brush to clean. Do not use a metal brush, damage to sealing area will result in leaks.
    • Carefully use a nylon brush to remove the old O-ring residue and use brake cleaner to rinse the O-ring residue out of the turbocharger tube to turbocharger O-ring bore and the turbocharger tube to engine O-ring bore. Inspect the area for deep scratches and gouges. Do not use a metal brush, damage to sealing area will result in leaks. Install new components if needed.
    • Connect the turbocharger oil supply tube to the turbocharger, then install and tighten the turbocharger oil supply tube bolt.

      Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

      Torque: 89 lb. in (10 Nm)

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61. Install the new turbocharger oil return tube-to-engine block gasket.

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62. Install a new turbocharger oil return tube O-ring seal, then lubricate with clean engine oil.

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    LHD AWD 

63. NOTE: Do not use a metal brush; damage to sealing area will result in leaks.
    • Carefully use a nylon brush to remove the old O-ring residue and use brake cleaner to rinse the O-ring residue out of the turbocharger O-ring bore. Inspect the area for deep scratches and gouges.
    • Position the turbocharger oil return tube behind the axle bracket.

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    LHD AWD/LHD RWD 

64. NOTE: Carefully use a nylon brush to remove the old O-ring residue and use brake cleaner to rinse the O-ring residue out of the turbocharger tube to engine O-ring bores for both the oil and coolant tubes. Inspect the area for deep scratches and gouges. Do not use a metal brush; damage to sealing area will result in leaks.

    Install the turbocharger, the new gasket, the bolt and the stud. Install the turbocharger coolant and oil supply tubes to the engine while installing the turbocharger.

    Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

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    LHD AWD 

65. NOTE: Do not use a metal brush, damage to sealing area will result in leaks.
    • Carefully use a nylon brush to remove the old O-ring residue and use brake cleaner to rinse the O-ring residue out of the turbocharger O-ring bore. Inspect the area for deep scratches and gouges.
    1. Install the turbocharger oil return tube, then install and tighten the turbocharger oil return tube bolts.

       Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

       Torque: 89 lb. in (10 Nm)

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    LHD RWD 

66. NOTE: Do not use a metal brush, damage to sealing area will result in leaks.
    • Carefully use a nylon brush to remove the old O-ring residue and use brake cleaner to rinse the O-ring residue out of the turbocharger O-ring bore. Inspect the area for deep scratches and gouges.
    1. Install the turbocharger oil return tube, then install and tighten the turbocharger oil return tube bolts.

       Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

       Torque: 89 lb. in (10 Nm)

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67. Install the right engine mount spacer, then install and tighten the bolts.

    Torque: Stage 1: Tighten to: : 66 lb. ft (90 Nm) Stage 2: Tighten an additional: : 90°

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    LHD AWD/LHD RWD 

68. Install the engine mounts. Refer to: Engine Mount LH . Refer to: Engine Mount RH .
69. 1. Install the front turbocharger stud.
    2. Tighten the turbocharger studs.

       Torque: 106 lb. in (12 Nm)

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70. Loosely install the turbocharger nuts.

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71. Tighten the turbocharger bolt.

    Torque: 44 lb. ft (60 Nm)

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72. 1. Tighten the turbocharger nut.

       Torque: 44 lb. ft (60 Nm)

    2. Tighten the turbocharger nut.

       Torque: 27 lb. ft (37 Nm)

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73. Re-tighten the turbocharger bolt.

    Torque: 44 lb. ft (60 Nm)

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74. 1. Re-tighten the turbocharger nuts.

       Torque: 44 lb. ft (60 Nm)

    2. Re-tighten the turbocharger nut

       Torque: 27 lb. ft (37 Nm)

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75. Install the turbocharger coolant supply tube, then install and tighten the turbocharger coolant supply tube bolt.

    Torque: 89 lb. in (10 Nm)

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76. Connect the turbocharger wastegate control hose and clamp.

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77. Install a new turbocharger coolant return tube O-ring seal and lubricate the new O-ring seal with clean engine coolant.

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78. Install and connect the turbocharger coolant return tube and clamp. Use the General Equipment: Hose Clamp Remover/Installer

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79. NOTE: Do not use a metal brush, damage to sealing area will result in leaks.
    • Carefully use a nylon brush to remove the old O-ring residue and use brake cleaner to rinse the O-ring residue out of the turbocharger O-ring bore. Inspect the area for deep scratches and gouges. Install new components if needed.

      Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

    1. Connect the turbocharger coolant return tube to the turbocharger, then install and tighten the bolt.

       Torque: 89 lb. in (10 Nm)

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80. NOTE: When installing the turbocharger oil supply tube into the engine block, use care not to damage the new turbocharger oil supply tube oil filter.

    Install the turbocharger oil supply tube to the engine, then install and tighten the turbocharger oil supply tube bolt.

    Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

    Torque: 89 lb. in (10 Nm)

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81. Install the following items:
    1. Refer to: Crankshaft Front Seal .
    2. Refer to: Generator - 3. 0L EcoBoost .
    3. Refer to: Coolant Pump .
    4. Refer to: Accessory Drive Belt Tensioner .
    5. Refer to: Accessory Drive Belt .

82. Rotate the crankshaft pulley bolt clockwise to position the camshaft lobe upward for the camshaft roller follower to be installed.

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83. NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed.
    NOTE: It may be necessary to push the valve down while compressing the spring.
    1. Install Special Service Tool: 303-1633 Remover, Roller Rocker Follower.
    2. Turn the knob on the special tool clockwise to depress the valve and spring.

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84. 1. Lubricate the camshaft roller follower with clean engine oil.
    2. Install the camshaft roller follower.
    3. Turn the knob on the special tool counterclockwise to raise the valve and spring. Remove Special Service Tool: 303-1633 Remover, Roller Rocker Follower.
    • Repeat steps for the remaining camshaft roller followers.

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85. Install the upper and lower radiator hoses and clamps.

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86. Attach the wiring harness retainer.
    • Position the ground cable and install the bolt.

      Torque: 89 lb. in (10 Nm)

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87. Position the ground cable and install the bolt.

    Torque: 106 lb. in (12 Nm)

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88. Install the following items:
    1. LH side. Refer to: Charge Air Cooler (CAC) Intake Pipe .
    2. Refer to: Oil Cooler .
    3. Refer to: Vacuum Pump .
    4. Refer to: Valve Cover LH .
    5. Refer to: Valve Cover RH .
    6. Refer to: Degas Bottle .
    7. Refer to: Oil Pan .

    LHD AWD 

89. NOTE: Secure the transmission to the transmission jack with a safety strap.
    NOTE: Make sure the transmission jack makes contact on the outer ribs of the transmission fluid pan.

    Using a high-lift transmission jack, support the transmission. Use the General Equipment: Transmission Jack. Use the General Equipment: Retaining Strap

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90. Remove the transfer case mounting bolts and nut.

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91. 1. Remove the bolts and the transmission support crossmember.
    2. Discard the bolts.

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92. Remove the transfer case to transmission bolts.

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93. Remove the transfer case to transmission bolts.

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94. NOTE: This step requires the aid of another technician.

    Remove the transfer case from the transmission.

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95. Lower the transmission jack 32 mm (1. 25 in). Use the General Equipment: Transmission Jack. Use the General Equipment: Retaining Strap

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96. NOTE: Make sure that a new component is installed.
    NOTE: Make sure that the O-ring is seated correctly.

    Install a new front axle pinion stem O-ring.

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97. NOTE: Make sure that a new component is installed.

    Install the new front axle pinion stem circlip.

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98. NOTE: Do not over-lubricate the driveshaft components. Using excessive grease may damage the driveshaft components.
    NOTE: Wipe off any excess grease.

    Lubricate the front drive axle splines with grease.

    Material: Motorcraft® Premium Long-Life Grease / XG-1-E1 (ESA-M1C75-B)

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99. NOTE: Transmission removed from view for clarity.

    Install the front drive shaft.

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100. NOTE: Maintain the suitable possible distance between components.

     Ensure the distance between the edge of plug-on yoke and the front axle pinion nut.

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101. NOTE: Transmission removed from view for clarity.

     Install the heat shield and the fasteners.

     Torque: 89 lb. in (10 Nm)

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     LHD RWD 

102. Remove and discard the transmission crossmember bolts.

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103. Lower the jack stand 32 mm (1. 25 in).

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     LHD AWD/LHD RWD 

104. • If removed, install new studs.

       Torque: 18 lb. ft (25 Nm)

     • Install the new gasket.

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105. NOTE: Body of vehicle removed from graphic for clarity.
     NOTE: AWD shown, RWD similar.

     Install the RH catalytic converter and the new nuts.

     Torque: 35 lb. ft (48 Nm)

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106. NOTE: AWD shown, RWD similar.
     • Connect the catalyst monitor sensor electrical connector.
     • Attach the wiring harness retainer.

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107. NOTE: AWD shown, RWD similar.
     • Connect the HO2S electrical connector.
     • Attach the wiring harness retainers.

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     LHD RWD 

108. Raise the jack stand.

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109. Install the new transmission crossmember bolts.

     Torque: 76 lb. ft (103 Nm)

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110. Remove the adjustable jack stand.

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     LHD AWD 

111. Raise the transmission jack 32 mm (1. 25 in). Use the General Equipment: Transmission Jack. Use the General Equipment: Retaining Strap

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112. NOTE: Do not over-lubricate the driveshaft components. Using excessive grease may damage the driveshaft components.
     NOTE: Wipe off any excess grease.

     Lubricate the transfer case inner splines with grease.

     Material: Motorcraft® High Temperature 4x4 Front Axle and Wheel Bearing Grease / XG-11 (WSS-M1C267-A1)

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113. NOTE: This step requires the aid of another technician.

     Install the transfer case onto the transmission.

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114. Install the transfer case to transmission bolts.

     Torque: 168 lb. in (19 Nm)

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115. Install the transfer case to transmission bolts.

     Torque: 168 lb. in (19 Nm)

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116. Install the transmission support crossmember and the new bolts.

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117. Install the transfer case mounting bolts and nut.

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118. Remove the high-lift transmission jack Use the General Equipment: Transmission Jack. Use the General Equipment: Retaining Strap

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119. Install the heat shield and the fasteners.

     Torque: 80 lb. in (9 Nm)

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120. Connect transfer case motor assembly electrical connector and position the wiring harness properly.

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121. Attach the transfer case vent hose.

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122. Ensure the electrical wiring harness is properly routing near U-joint and not contacting to driveshaft at any point.

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123. NOTE: Do not over articulate the driveshaft or damage may occur.
     NOTE: Do not force the flex coupling bushing on the transfer case output shaft or damage will occur.
     1. Align the index-mark on driveshaft flex coupling to the transfer case flange.
     2. Install the new driveshaft flex coupling to transfer case flange bolts.

        Torque: 81 lb. ft (110 Nm)

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124. If equipped. Install the transfer case heat shield and the bolts.

     Torque: 21 lb. ft (28 Nm)

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125. Install the LH halfshaft. Refer to: Halfshaft .

     LHD AWD/LHD RWD 

126. Install the exhaust mounting bracket and the fasteners

     Torque: 18 lb. ft (25 Nm)

     Courtesy of FORD MOTOR COMPANY

127. Install the following items:
     1. LH and RH exhaust flexible pipes. Refer to: Exhaust Flexible Pipe .
     2. Front wheels and tires. Refer to: Wheel and Tire .

128. Install a new engine oil filter and fill the engine with clean engine oil. Refer to: Engine Oil Draining and Filling .
129. Connect the battery ground cable. Refer to: Battery Disconnect and Connect .
130. Pressurize the fuel system. Refer to: Fuel System Pressure Release .
131. Fill and bleed the engine cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .
132. Use the Powertrain Control Module (PCM) Misfire Monitor Profile Correction routine in the diagnostic scan tool.
133. Start and check the exhaust system for leaks.