Cylinder Head: Assembly

WARNING: This page is about a different car, the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E550 Super Duty, 2003 Ford E450 Super Duty, and 2003 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

ALL CYLINDER HEADS

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 that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.

CAUTION: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.

NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.

Clean the cylinder head sealing surfaces.
1. Remove any large deposits of silicone or gasket material with a plastic scraper.
2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.
3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
4. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
Lubricate the camshaft journals with clean engine oil.

Fig 1: Lubricating Camshaft Journals With Clean Engine Oil
Courtesy of FORD MOTOR CO.
Install the camshaft and the camshaft bearing caps in their original locations.
- Lubricate the camshaft bearing caps with clean engine oil.
- Position the camshaft bearing caps.
- Install the bolts loosely.
Fig 2: Installing Camshaft And Camshaft Bearing Caps
Courtesy of FORD MOTOR CO.
Tighten the bolts in the sequence shown.

Fig 3: Tightening Sequence Of Camshaft Bearing Caps Bolts
Courtesy of FORD MOTOR CO.

NOTE: Lubricate the valve stems using clean engine oil.

Fig 4: Installing Valves In The Valve Guides

Courtesy of FORD MOTOR CO.

Install the valves in the valve guides located in the cylinder head.
Use the special tools to install the valve stem seals.

Fig 5: Installing Valve Stem Seals
Courtesy of FORD MOTOR CO.
Install the valve springs and the valve spring retainers onto the valves.

Fig 6: Installing Valve Springs And Valve Spring Retainers Onto Valves
Courtesy of FORD MOTOR CO.
Install the special tool between the valve spring coils to prevent valve stem seal damage.

Fig 7: Installing Special Tool Between Valve Spring Coils
Courtesy of FORD MOTOR CO.
Use the special tool to compress the valve springs. Install the valve spring retainer keys.

Fig 8: Installing Valve Spring Retainer Keys
Courtesy of FORD MOTOR CO.

NOTE: Lubricate the hydraulic lash adjusters using clean engine oil.

Fig 9: Installing Hydraulic Lash Adjusters

Courtesy of FORD MOTOR CO.

Install the hydraulic lash adjusters in their original locations.
Remove the special tool, unless the cylinder head is to be installed in-vehicle.

Fig 10: Removing Special Tool
Courtesy of FORD MOTOR CO.

CYLINDER HEADS FOR IN-VEHICLE INSTALLATION

NOTE: Lubricate the camshaft roller followers using clean engine oil.

Fig 11: Installing Camshaft Roller Followers

Courtesy of FORD MOTOR CO.

Install the camshaft roller followers.
1. Install the special tool.
2. Compress the valve spring.
3. Install the camshaft roller followers in their original locations.
Remove the special tool.

Fig 12: Removing Special Tool
Courtesy of FORD MOTOR CO.
Loosely install the special tool.

Fig 13: Installing Special Tool
Courtesy of FORD MOTOR CO.