Lincoln Navigator: Engine - 3.5L EcoBoost (272kW/370PS) / Cylinder Head. Disassembly and Assembly of Subassemblies

Special Tool(s) / General Equipment

	303-1249 Valve Spring Compressor TKIT-2006UF-FLM TKIT-2006UF-ROW
	303-1418 Compressor, Valve Spring TKIT-2008ET-FLM TKIT-2008ET-ROW
	303-1567 Sizer, Teflon Seal TKIT-2010C-FLM
	303-300 (T87C-6565-A) Set, Valve Spring Compressor TKIT-1988-FESTIVA T88C-1000-ST TKIT-1988-TRACER TKIT-2009TC-F
	303-350 (T89P-6565-A) Compressor, Valve Spring TKIT-1990-LMH TKIT-1989-F TKIT-1989-FM TKIT-1989-FLM
	303-470 (T94P-6510-CH) Installer, Valve Stem Oil Seal TKIT-1994-LMH/MH2 TKIT-2009TC-F TKIT-1994-FH/FMH/FLMH
	307-005 (T59L-100-B) Slide Hammer
	310-205 Fuel Injector Brush
	310-206 Remover, Fuel Injector TKIT-2009A-FLM
	310-207 Installer, Fuel Injector Seal Assembly TKIT-2009A-FLM

Materials

DISASSEMBLY

NOTICE: The turbocharger compressor vanes can be damaged by even the smallest particles. When removing any turbocharger or engine air intake system component, ensure that no debris enters the system. Failure to do so may result in damage to the turbocharger.

NOTICE: 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, can cause engine failure.

LH cylinder head

1. • Remove the nuts and the exhaust manifold.
     
   • Discard the nuts.
     

1. • Remove the discard the exhaust manifold gasket.
     
   • Remove and discard the studs.
     

1. • Clean and inspect the exhaust manifold.
     Refer to: Exhaust Manifold Cleaning and Inspection (303-00 Engine System - General Information, General Procedures).
     

   • NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces.

     Clean the exhaust manifold mating surface of the cylinder head with metal surface prep wipes. Follow the directions on the packaging.
     Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B

1. 1. Remove and discard the direct injection fuel rail mounting bolts.
      

   2. NOTICE: Pull out the fuel rails in the direction of the fuel injector axis or damage may occur to the fuel injectors.

      NOTE: When removing the fuel rails, the fuel injectors may remain in the cylinder heads and require the use of a Fuel Injector Remover tool to extract. Wiggling the injector by hand to break it loose may allow the injector to be removed by hand.

      Remove the direct injection fuel rail and the fuel injectors.
      

1. Disconnect the fuel injector electrical connectors.
   

1. • Release the fuel injector retaining clips.
     
   • Remove the fuel injectors from the fuel rail.
     

1. Remove and discard the clips from all of the fuel injectors including any injectors that have remained in the cylinder head.
   

1. • Remove and discard the fuel injector O-ring seals.
     

   • NOTE: Note the correct orientation of the fuel injector support rings for correct installation of the new fuel injector support rings.

     Remove and discard the fuel injector support rings.
     

1. NOTICE: Use care when removing the lower Teflon® seals, not to scratch, nick or gouge the fuel injectors.

   NOTICE: Do not attempt to cut the lower Teflon® seal without first pulling it away from the fuel injector or damage to the injector may occur.

   • Pull the lower Teflon® seal away from the injector.
     
   • Carefully cut and discard the lower fuel injector Teflon® seals.
     

RH cylinder head

1. Remove the EGR to exhaust manifold connector.
   

1. • Remove the nuts and the exhaust manifold.
     
   • Discard the nuts.
     

1. Remove and discard the studs and the exhaust manifold gasket.
   

1. • Clean and inspect the exhaust manifold.
     Refer to: Exhaust Manifold Cleaning and Inspection (303-00 Engine System - General Information, General Procedures).
     

   • NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces.

     Clean the exhaust manifold mating surface of the cylinder head with metal surface prep wipes. Follow the directions on the packaging.
     Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B

1. 1. Remove and discard the direct injection fuel rail mounting bolts.
      

   2. NOTICE: Pull out the fuel rails in the direction of the fuel injector axis or damage may occur to the fuel injectors.

      NOTE: When removing the fuel rails, the fuel injectors may remain in the cylinder heads and require the use of a Fuel Injector Remover tool to extract. Wiggling the injector by hand to break it loose may allow the injector to be removed by hand.

      Remove the direct injection fuel rail and the fuel injectors.
      

1. Disconnect the fuel injector electrical connectors.
   

1. • Release the fuel injector retaining clips.
     
   • Remove the fuel injectors from the fuel rail.
     

1. Remove and discard the clips from all of the fuel injectors including any injectors that have remained in the cylinder head.
   

1. • Remove and discard the fuel injector O-ring seals.
     

   • NOTE: Note the correct orientation of the fuel injector support rings for correct installation of the new fuel injector support rings.

     Remove and discard the fuel injector support rings.
     

1. NOTICE: Use care when removing the lower Teflon® seals, not to scratch, nick or gouge the fuel injectors.

   NOTICE: Do not attempt to cut the lower Teflon® seal without first pulling it away from the fuel injector or damage to the injector may occur.

   • Pull the lower Teflon® seal away from the injector.
     
   • Carefully cut and discard the lower fuel injector Teflon® seals.
     

All cylinder heads

1. NOTICE: Use minimal force to remove the fuel injectors that remained in the cylinder head with the Fuel Injector Remover tool or damage to the fuel injector assembly may occur.

   Using the special tools, remove the fuel injectors that remained in the cylinder head.
   Use Special Service Tool: 307-005 (T59L-100-B)  Slide Hammer. , 310-206  Remover, Fuel Injector.

1. NOTICE: Make sure to thoroughly clean any residual fuel or foreign material from the cylinder head, block and the general surrounding area of the fuel rails and injectors.

   NOTICE: Do not use compressed air to clean the tip of the fuel injector.

   NOTICE: Do not use a brush to clean the tip of the fuel injector.

   Using the special tool, clean the cylinder head fuel injector bores.
   Use Special Service Tool: 310-205  Fuel Injector Brush.

1. Remove the spark plugs.
   

1. NOTE: LH shown, RH similar.

   NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations.

   Using the special tools, remove the valve collet, valve spring retainer and the valve spring.
   Use Special Service Tool: 303-300 (T87C-6565-A)  Set, Valve Spring Compressor. , 303-350 (T89P-6565-A)  Compressor, Valve Spring. , 303-1249  Valve Spring Compressor. , 303-1418  Compressor, Valve Spring.

1. Remove and discard the valve stem seal.
   

1. Remove the valve.
   

1. Repeat the previous 3 steps for each valve.
   

ASSEMBLY

All cylinder heads

1. Install the valve.
   

1. NOTE: Lubricate the valve stem seal with clean engine oil prior to installation.

   Using the special tool, install the valve stem seal.
   Refer to: Specifications (303-01) .
   Use Special Service Tool: 303-470 (T94P-6510-CH)  Installer, Valve Stem Oil Seal.

1. Using the special tools, install the valve spring, valve spring retainer and the valve collet.
   Use Special Service Tool: 303-300 (T87C-6565-A)  Set, Valve Spring Compressor. , 303-350 (T89P-6565-A)  Compressor, Valve Spring. , 303-1249  Valve Spring Compressor. , 303-1418  Compressor, Valve Spring.

1. Repeat the previous 3 steps for each valve.
   

1. Install the spark plugs.
   Torque: 133 lb.in (15 Nm)

RH cylinder head

1. NOTICE: Do not lubricate the new lower Teflon® fuel injector seals.

   1. Install the Arbor on the fuel injector tips.
      Use Special Service Tool: 310-207  Installer, Fuel Injector Seal Assembly.

   2. NOTICE: Once the Teflon® seal is installed on the Teflon® Seal Guide, it should immediately be installed onto the fuel injector to avoid excessive expansion of the Teflon® seal.

      NOTE: Make sure that new lower fuel injector Teflon® seals are installed.

      Install the new Teflon® seals onto the Arbor, using the Pusher Tool (part of the Fuel Injector Seal Installer), slide the Teflon® seals along the Arbor.
      
   3. Using the Pusher Tool, slide the Teflon® seals off of the Teflon® Seal Guide and into the groove on the fuel injectors.
      Use Special Service Tool: 310-207  Installer, Fuel Injector Seal Assembly.

1. NOTICE: Install the fuel injectors into the cylinder head within 15 minutes of sizing the seals due to Teflon® seal expansion.

   NOTE: Make sure the Teflon® seal is fully seated in the groove on the fuel injector before sizing the Teflon® seal.

   1. Some Teflon® seal massaging with your fingers before the Teflon® seal sizer tool is installed will aid in installing the Teflon® seal sizer tool.
      
   2. Position the Teflon® Seal Sizer tool with the larger opening towards the Teflon® seal. Push while turning the Teflon® Seal Sizer tool 180 degrees.
      Use Special Service Tool: 303-1567  Sizer, Teflon Seal.
   3. Once the Teflon® Seal Sizer tool is installed, check and make sure the Teflon® seal is in the sizing portion of the Teflon® Seal Sizer tool. After one minute, turn the Teflon® Seal Sizer tool back 180 degrees and remove.
      
   4. After one minute, turn the Teflon® seal sizer tool back 180 degrees and remove.
      

1. 1. NOTICE: The large diameter step of the backup ring must go up towards the new O-ring seal. Improperly installed backup rings may cause the fuel system to leak.

      Install the fuel injector backup ring.
      

   2. NOTICE: Use fuel injector O-ring seals that are made of special fuel-resistant material. The use of ordinary O-ring seals may cause the fuel system to leak. Do not reuse the O-ring seals.

      NOTE: Do not lubricate the new lower Teflon® fuel injector seals.

      Install the new fuel injector O-ring seals. Lubricate the new fuel injector O-ring seals with clean engine oil.
      Refer to: Specifications (303-01) .
      
   3. Install the new the fuel injector retaining clip.
      

1. NOTICE: The anti-rotation finger of the fuel injector must slip into the groove of the fuel rail cup.

   Install the fuel injectors into the fuel rail.
   

1. Connect the fuel injector electrical connectors.
   

1. NOTE: Do not lubricate the new lower Teflon® fuel injector seals.

   NOTE: Make sure that new fuel rail mounting bolts are installed.

   NOTE: Push down on the fuel rail above the injectors.

   • Install the fuel injectors and direct injection fuel rail assembly into the cylinder head. Tighten the bolts in sequence shown in 2 stages.
     Torque:
       Stage 1:  89 lb.in (10 Nm)
       Stage 2:  45°

1. NOTE: Install short end of stud into cylinder head assembly.

   • Loosely install the new studs into the cylinder head.
     
   • Tighten the studs.
     Torque: 115 lb.in (13 Nm)
   • Install the new exhaust manifold gasket.
     

1. Install the exhaust manifold and the new nuts. Tighten the nuts in sequence shown in 2 stages.
   Torque:
     Stage 1:  142 lb.in (16 Nm)
     Stage 2:  16 lb.ft (22 Nm)

1. Install the EGR to exhaust manifold connector.
   Torque: 125 lb.ft (170 Nm)

LH cylinder head

1. NOTICE: Do not lubricate the new lower Teflon® fuel injector seals.

   1. Install the Arbor on the fuel injector tips
      Use Special Service Tool: 310-207  Installer, Fuel Injector Seal Assembly.

   2. NOTICE: Once the Teflon® seal is installed on the Teflon® Seal Guide, it should immediately be installed onto the fuel injector to avoid excessive expansion of the Teflon® seal.

      NOTE: Make sure that new lower fuel injector Teflon® seals are installed.

      Install the new Teflon® seals onto the Arbor, using the Pusher Tool (part of the Fuel Injector Seal Installer), slide the Teflon® seals along the Arbor.
      
   3. Using the Pusher Tool, slide the Teflon® seals off of the Teflon® Seal Guide and into the groove on the fuel injectors.
      Use Special Service Tool: 310-207  Installer, Fuel Injector Seal Assembly.

1. NOTICE: Install the fuel injectors into the cylinder head within 15 minutes of sizing the seals due to Teflon® seal expansion.

   NOTE: Make sure the Teflon® seal is fully seated in the groove on the fuel injector before sizing the Teflon® seal.

   1. Some Teflon® seal massaging with your fingers before the Teflon® seal sizer tool is installed will aid in installing the Teflon® seal sizer tool.
      
   2. Position the Teflon® Seal Sizer tool with the larger opening towards the Teflon® seal. Push while turning the Teflon® Seal Sizer tool 180 degrees.
      Use Special Service Tool: 303-1567  Sizer, Teflon Seal.
   3. Once the Teflon® Seal Sizer tool is installed, check and make sure the Teflon® seal is in the sizing portion of the Teflon® Seal Sizer tool. After one minute, turn the Teflon® Seal Sizer tool back 180 degrees and remove.
      
   4. After one minute, turn the Teflon® seal sizer tool back 180 degrees and remove.
      

1. 1. NOTICE: The large diameter step of the backup ring must go up towards the new O-ring seal. Improperly installed backup rings may cause the fuel system to leak.

      Install the fuel injector backup ring.
      

   2. NOTICE: Use fuel injector O-ring seals that are made of special fuel-resistant material. The use of ordinary O-ring seals may cause the fuel system to leak. Do not reuse the O-ring seals.

      NOTE: Do not lubricate the new lower Teflon® fuel injector seals.

      Install the new fuel injector O-ring seals. Lubricate the new fuel injector O-ring seals with clean engine oil.
      Refer to: Specifications (303-01) .
      
   3. Install the new the fuel injector retaining clip.
      

1. NOTICE: The anti-rotation finger of the fuel injector must slip into the groove of the fuel rail cup.

   Install the fuel injectors into the fuel rail.
   

1. Connect the fuel injector electrical connectors.
   

1. NOTE: Do not lubricate the new lower Teflon® fuel injector seals.

   NOTE: Make sure that new fuel rail mounting bolts are installed.

   NOTE: Push down on the fuel rail above the injectors.

   • Install the fuel injectors and direct injection fuel rail assembly into the cylinder head. Tighten the bolts in sequence shown in 2 stages.
     Torque:
       Stage 1:  89 lb.in (10 Nm)
       Stage 2:  45°
   • Connect the fuel injector electrical connectors.
     

1. NOTE: Install short end of stud into cylinder head assembly.

   • Loosely install the new studs into the cylinder head.
     
   • Tighten the studs.
     Torque: 115 lb.in (13 Nm)
   • Install the new exhaust manifold gasket.
     

1. Install the exhaust manifold and the new nuts. Tighten the nuts in sequence shown in 2 stages.
   Torque:
     Stage 1:  142 lb.in (16 Nm)
     Stage 2:  16 lb.ft (22 Nm)