Ford Escape Quiz
Powertrain

Removal and Installation – Cylinder Head

In this manual: Powertrain
General Information — 26Chassis — 160Powertrain — 323Electrical — 356Body and Paint — 290
56steps
~341min
5/5difficulty
1special tools
010203040502821N·mlb·ft
Tightening torque found on this page
Done 0 of 56

Special Service Tools / General Equipment

303-476 (T94P-9472-A)
Socket, Exhaust Gas Oxygen Sensor
TKIT-1994-LM/M
TKIT-1994-F
TKIT-1994-FLM/FM
Oil Drain Equipment
Hose Clamp Removal/Installation Tool

Materials

Name Specification
Motorcraft® High Performance Engine RTV Silicone
TA-357		 ALL-M4G323-A6
Motorcraft® High-Temperature Nickel Anti-Seize Lubricant
XL-2		 -
Motorcraft® Penetrating and Locking Lubricant
XL-1		 -

Removal

  1. Position the vehicle in NEUTRAL on the lift.
    Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).
  2. Relieve the fuel system pressure.
    Refer to: Fuel System Pressure Release (310-00C Fuel System – General Information, General Procedures).
  3. Drain the cooling system.
    Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03C Engine Cooling – General Procedures).
    • Remove the oil drain plug and drain the engine oil.
      Use the general equipment: oil draining equipment
    • Install the oil drain plug.
      Torque: 21 lb-ft (28 N·m)
  5. Remove and discard the engine oil filter.
  6. Disconnect the spring lock coupling.
    Refer to: Spring Lock Couplings (310-00C Fuel System – General Information, General Procedures).
  7. Remove the nuts, bolts, and the exhaust gas recirculation (EGR) cooler inlet tube.
  8. Discard the EGR cooler inlet tube gaskets.

    • Disconnect the HO2S electrical connector.
    • Remove the bolts and the wire harness brackets.
    • Remove the HO2S.
      Use the special service tool: 303-476 (T94P-9472-A) Oxygen Sensor Socket.
      Material: Motorcraft® Penetrating and Locking Lubricant / XL-1
  10. Remove the bolts and the exhaust manifold heat shield.
  11. Remove the nuts and the bracket.

  12. NOTICE: Make sure the flex exhaust pipe is not twisted or bent by force.

    Support the flex exhaust pipe with a support film or a suitable bar.
  13. Remove the outlet clamp.
  14. Make sure the mating surfaces are clean and free of foreign material.
  15. Unscrew the exhaust manifold bracket mounting bolts.
  16. Remove and discard the nuts. Reinstall the exhaust manifold.
  17. Remove and discard the exhaust manifold gasket.
  18. Remove and discard the exhaust manifold studs.
  19. Remove the following components:
    1. Remove the air cleaner outlet tube.
      Refer to: Air Cleaner Outlet Tube (303-12C Intake Air Distribution and Filtering, Removal and Installation).
    2. Remove the intake manifold.
      Refer to: Intake Manifold (303-01C Engine, Removal and Installation).
    3. Remove the valve cover.
      Refer to: Valve Cover (303-01C, Removal and Installation).
    4. Remove the camshafts.
      Refer to: Camshafts (303-01C Engine – 2.0L, Removal and Installation).
  20. Remove the ground wire.
  21. Remove the valve lifters.
  22. Inspect the valve lifters.

  23. NOTICE: Place absorbent towels under the radiator hose to prevent coolant from contacting the ISC.

    Disconnect the coolant hose.
    Use the general equipment: hose clamp removal/installation tool.
    • Remove the bolts and the cylinder head.
    • Discard the bolts.
  25. Remove and discard the cylinder head gasket.

Installation

  1. Clean the cylinder block sealing surfaces.
    Refer to: RTV Sealing Surface Cleaning and Preparation (303-00 Engine System - General Information, General Procedures).
  2. Clean the cylinder block sealing surfaces.
    Refer to: RTV Sealing Surface Cleaning and Preparation (303-00 Engine System - General Information, General Procedures).
  3. Check the cylinder head for distortion.
    Refer to: Cylinder Head Distortion (303-00 Engine System - General Information, General Procedures).
  4. Check the cylinder block for distortion.
    Refer to: Cylinder Block Distortion (303-00 Engine System - General Information, General Procedures).
  5. Apply a 6 mm (0.24 in) bead of silicone sealant.
    Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
  6. Install a new cylinder head gasket.
  7. Install the cylinder head and bolts. Tighten in the sequence shown in 5 steps.
    Refer to: Specifications (Engine 303-01C, Specifications).
    Torque:
    Step 1: 62 lb-in (7 N·m)
    Step 2: 133 lb-in (15 N·m)
    Step 3: 33 lb-ft (45 N·m)
    Step 4: 90°
    Step 5: 90°
  8. Remove the excess sealant at the junction of the cylinder block and the cylinder head.
  9. Connect the coolant hose.
    Use common service equipment: hose clamp removal and installation tool.
  10. Lubricate with clean engine oil and install the valve lifters.
    Refer to: Specifications (Engine 303-01C, Specifications).
  11. Install the ground wire.
    Torque: 133 lb-in (15 N·m)
  12. Install the following components:
    1. Install the camshafts.
      Refer to Camshafts (Engine 303-01C, Removal and Installation).
    2. Install the valve cover.
      Refer to: Valve Cover (Engine 303-01C, Removal and Installation).
    3. Install the intake manifold.
      Refer to: Intake Manifold (303-01C Engine, Removal and Installation).
    4. Install the air cleaner outlet tube.
      Refer to: Air Cleaner Outlet Tube (303-12C Intake Air Distribution and Filtering, Removal and Installation).
  13. Install new exhaust manifold studs.
    Torque: 150 lb-in (17 N·m)
  14. Install a new exhaust manifold gasket.
  15. Install the exhaust manifold and new nuts.
    Torque: 41 lb-ft (55 N·m)
  16. Install the exhaust manifold bracket and bolts.
    Torque: 18 lb-ft (25 N·m)
  17. Install the exhaust clamp.
    Torque: 17 lb-ft (23 N·m)
  18. Install the bracket and nuts.
    Torque: 35 lb-ft (48 N·m)

  19. NOTICE: Make sure the flex exhaust pipe is not twisted or bent by force.

    Remove the flex exhaust pipe support.
  20. Install the exhaust manifold heat shield and bolts.
    Torque: 89 lb-in (10 N·m)

    • Calculate the correct torque wrench setting for the following torque. Refer to the Torque Wrench Adapter Formula in Apex. Install the HO2S sensor.
      Use special service tool: 303-476 (T94P-9472-A) Exhaust Gas Oxygen Sensor Socket.
      Material: Motorcraft® High Temperature Nickel Anti-Seize Lubricant / XL-2
      Torque: 35 lb-ft (48 N·m)
    • Install the wire harness bolts and brackets.
    • Connect the HO2S sensor electrical connector.
  22. Clean and inspect the gasket surface and studs. Replace the studs if necessary.
    Torque: 159 lb-in (18 N·m)
  23. Install new exhaust gas recirculation (EGR) cooler inlet pipe gaskets.
  24. Install the EGR cooler inlet pipe and tighten the fasteners by hand.
  25. Torque:
    1: 89 lb-in (10 N·m)
    2: 18 lb-ft (24 N·m)
    1: 18 lb-ft (24 N·m)
    3: 89 lb-in (10 N·m)
    4: 18 lb-ft (24 N·m)
    3: 18 lb-ft (24 N·m)
  26. Connect the spring-lock coupling.
    Refer to: Spring-Lock Couplings (310-00C Fuel System - General Information, General Procedures).
  27. Install a new oil filter.
    Refer to: Specifications (Engine 303-01C, Specifications).
    Torque:
    Step 1: 71 lb-in (8 N·m)
    Step 2: 180°
  28. Fill the engine with clean engine oil.
    Refer to: Specifications (Engine 303-01C, Specifications).
  29. Fill and bleed the cooling system.
    Refer to: Engine Cooling System Draining, Vacuum Filling and Air Bleeding (303-03C Engine Cooling - General Procedures).
  31. Road test the vehicle.

Test yourself

A quick Ford Escape quiz: every answer comes with an explanation and a link to the manual page.