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Home >> Ford >> 2000 >> Contour SE, 2.0 3, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1154 (Engine -- 4.6L (2V)) >> Removal >> Cylinder Heads

Cylinder Heads

WARNING: This page is about a different car, the 2005 Mercury Mountaineer and 2005 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL CHART

G03886657
 Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D)
G03905746
 Remover, Crankshaft Front Seal 303-107 (T74P-6700-A)
G03886005
 Remover/Installer, Cylinder Head 303-572 (T97T-6000-A)
G03885361
 Compressor, Valve Spring 303-567 (T97P-6565-AH)
G03885376
 Spacer, Valve Spring 303-382 (T91P-6565-AH)
MATERIAL CHART

Item Specification
Motorcraft Silicone Gasket Remover ZC-30 -
Motorcraft Metal Surface Prep ZC-31 -
  1. Remove the engine. For additional information, refer to ENGINE .
  2. Remove the bolts and the flexplate.
    Fig 1: Identifying Bolts And Flexplate
    G03885612Courtesy of FORD MOTOR CO.
  3. Remove the spacer plate.
    Fig 2: Removing Spacer Plate
    G03947909Courtesy of FORD MOTOR CO.
  4. Install the engine on a suitable engine stand.
  5. Rotate the belt tensioner and remove the accessory drive belt.
    Fig 3: Rotating Accessory Drive Belt Tensioner Clockwise
    G03886148Courtesy of FORD MOTOR CO.
  6. Disconnect the oil pressure sensor electrical connector.
  7. Remove the nuts and position the wiring harness bracket aside.
    Fig 4: Removing Nuts
    G03947735Courtesy of FORD MOTOR CO.
  8. Remove the power steering hose support bracket.
    Fig 5: Removing Power Steering Hose Support Bracket
    G03947620Courtesy of FORD MOTOR CO.
  9. Disconnect the return and pressure hoses from the power steering pump.
    Fig 6: Disconnecting Return And Pressure Hoses
    G03947737Courtesy of FORD MOTOR CO.
  10. Remove the bolts and the power steering pump.
    Fig 7: Removing Power Steering Pump
    G03947738Courtesy of FORD MOTOR CO.
  11. Remove the nut and position the radio capacitor and ground cable aside.
    Fig 8: Removing Nut
    G03947739Courtesy of FORD MOTOR CO.
  12. Remove the power steering reservoir and bracket from the stud.
    Fig 9: Removing Power Steering Reservoir And Bracket From Stud
    G03947740Courtesy of FORD MOTOR CO.
  13. Disconnect the A/C compressor and crankshaft position (CKP) sensor electrical connectors.
    Fig 10: Disconnecting A/C Compressor And Crankshaft Position (CKP) Sensor Electrical Connectors
    G03947920Courtesy of FORD MOTOR CO.
  14. Disconnect the wiring harness retainers.
    Fig 11: Disconnecting Wiring Harness Retainers
    G03947742Courtesy of FORD MOTOR CO.
  15. Detach the wiring harness retainer from the A/C tube.
    Fig 12: Removing Wiring Harness Retainer From A/C Tube
    G03947743Courtesy of FORD MOTOR CO.
  16. Remove the bolt and position the wiring harness aside.
    Fig 13: Removing Bolt And Position Wiring Harness Aside
    G03947744Courtesy of FORD MOTOR CO.
  17. Remove the crankcase air inlet tube.
    Fig 14: Removing Crankcase Air Inlet Tube
    G03947745Courtesy of FORD MOTOR CO.
  18. Remove the nut and the upper radiator hose bracket and position the radio interference capacitor aside.
    Fig 15: Removing Upper Radiator Hose Bracket
    G03947621Courtesy of FORD MOTOR CO.
  19. Remove the bolts and the idler pulleys.
    Fig 16: Removing Idler Pulleys
    G03947747Courtesy of FORD MOTOR CO.
  20. Disconnect the generator electrical connectors and pin-type retainer.
    Fig 17: Disconnecting Generator Electrical Connectors
    G03947748Courtesy of FORD MOTOR CO.
  21. Remove the bolts and the bracket.
    Fig 18: Removing Bolts And Bracket
    G03947749Courtesy of FORD MOTOR CO.
  22. Remove the bolts and the generator.
    Fig 19: Removing Bolts And Generator
    G03947750Courtesy of FORD MOTOR CO.
  23. Disconnect the electrical connector and remove the bolt and the camshaft position (CMP) sensor.
    Fig 20: Disconnecting Electrical Connector
    G03947751Courtesy of FORD MOTOR CO.
  24. Remove the bolts and the coolant pump pulley.
  25. Remove the exhaust gas recirculation (EGR) system module-to-manifold tube.
    Fig 21: Removing Coolant Pump Pulley
    G03947752Courtesy of FORD MOTOR CO.
  26. Remove the RH exhaust manifold heat shield.
    Fig 22: Removing RH Exhaust Manifold Heat Shield
    G03947753Courtesy of FORD MOTOR CO.
  27. Remove the RH exhaust manifold.
    1. Remove the 8 nuts.
    2. Remove the RH exhaust manifold.
    3. Remove and discard the RH exhaust manifold gasket.
      Fig 23: Removing RH Exhaust Manifold
      G03947754Courtesy of FORD MOTOR CO.
  28. Remove the LH exhaust manifold heat shield.
    Fig 24: Removing LH Exhaust Manifold Heat Shield
    G03947755Courtesy of FORD MOTOR CO.
  29. Remove the LH exhaust manifold.
    1. Remove the 8 nuts.
    2. Remove the LH exhaust manifold.
    3. Remove and discard the LH exhaust manifold gasket.
      Fig 25: Removing LH Exhaust Manifold
      G03947756Courtesy of FORD MOTOR CO.
  30. Remove the bolt and the oil level indicator tube.
    Fig 26: Locating Oil Level Indicator Tube Mounting Bolt
    G03906387Courtesy of FORD MOTOR CO.
  31. Clean and inspect the exhaust manifolds. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  32. Remove the bolt and the brake booster vacuum hose.
    Fig 27: Removing Brake Booster Vacuum Hose
    G03947758Courtesy of FORD MOTOR CO.
  33. Disconnect the throttle position (TP) sensor and the electronic throttle body electrical connectors.
    Fig 28: Disconnecting Throttle Position (TP) Sensor
    G03947759Courtesy of FORD MOTOR CO.
  34. Remove the positive crankcase ventilation (PCV) tube and disconnect the vacuum tube from the throttle body adapter.
    Fig 29: Removing Positive Crankcase Ventilation (PCV) Tube
    G03947760Courtesy of FORD MOTOR CO.
  35. Disconnect the EGR system module and fuel pressure sensor vacuum fittings.
    • Remove the vacuum harness from the engine.
      Fig 30: Removing Vacuum Harness From Engine
      G03947558Courtesy of FORD MOTOR CO.
  36. Disconnect the EGR system module and fuel pressure sensor electrical connectors.
    Fig 31: Disconnecting EGR System Module And Fuel Pressure Sensor Electrical Connectors
    G03947762Courtesy of FORD MOTOR CO.
  37. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
    Fig 32: Disconnecting Cylinder Head Temperature (CHT) Sensor Electrical Connector
    G03947763Courtesy of FORD MOTOR CO.
  38. Disconnect the knock sensor (KS) electrical connector and the wiring harness pin-type retainer.
    Fig 33: Locating Knock Sensor (KS) Electrical Connector
    G03881828Courtesy of FORD MOTOR CO.
  39. Disconnect the coolant hoses.
    Fig 34: Disconnecting Coolant Hoses
    G03947765Courtesy of FORD MOTOR CO.
  40. Disconnect the coolant hose.
    Fig 35: Disconnecting Coolant Hose
    G03947766Courtesy of FORD MOTOR CO.
  41. Remove the bolts and the electronic throttle body and adapter.
    Fig 36: Removing Electronic Throttle Body And Adapter
    G03947767Courtesy of FORD MOTOR CO.
  42. Disconnect the RH fuel injector, coil and ground electrical connectors and the wiring harness retainers.
    Fig 37: Disconnecting RH Fuel Injector, Coil And Ground Electrical Connectors
    G03947561Courtesy of FORD MOTOR CO.
  43. Disconnect the LH fuel injector and coil pack electrical connectors and the fuel charging wiring harness retainers.
    Fig 38: Disconnecting LH Fuel Injector And Coil Pack Electrical Connectors
    G03947562Courtesy of FORD MOTOR CO.
  44. Disconnect the wiring harness retainers.
    Fig 39: Disconnecting Wiring Harness Retainers
    G03947770Courtesy of FORD MOTOR CO.
  45. Disconnect the ground wire.
    Fig 40: Disconnecting Ground Wire
    G03947560Courtesy of FORD MOTOR CO.
  46. Disconnect all remaining wiring harness retainers and remove the fuel charging wiring harness.
    47. NOTE: LH is shown, RH is similar.
    Fig 41: Removing Ignition Coils
    G03947564Courtesy of FORD MOTOR CO.
  47. Remove the bolts and all 8 ignition coils.
  48. Remove the bolts and the thermostat housing.
    Fig 42: Removing Thermostat Housing
    G03947773Courtesy of FORD MOTOR CO.
  49. Remove the 9 bolts and the intake manifold.
    Fig 43: Removing Bolts And Intake Manifold
    G03947774Courtesy of FORD MOTOR CO.
  50. Remove the intake manifold gaskets.
    Fig 44: Removing Intake Manifold Gaskets
    G03947775Courtesy of FORD MOTOR CO.
    51. 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 which make leak paths.
  51. Clean the sealing surfaces.
  52. Remove the bolts and the LH engine mount.
    Fig 45: Removing LH Engine Mount
    G03947776Courtesy of FORD MOTOR CO.
  53. Remove the bolts and the RH engine mount.
    Fig 46: Removing RH Engine Mount
    G03947777Courtesy of FORD MOTOR CO.
  54. Remove the RH cylinder block drain plug.
    • Reinstall the drain plug after draining the coolant.
      Fig 47: Removing RH Cylinder Block Drain Plug
      G03947778Courtesy of FORD MOTOR CO.
  55. Remove the LH cylinder block drain plug.
    • Reinstall the drain plug after draining the coolant.
      Fig 48: Removing LH Cylinder Block Drain Plug
      G03947779Courtesy of FORD MOTOR CO.
    56. 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 which make leak paths.
    NOTE: There are several kinds of bolts used in fastening the valve cover. The bolts must be installed in their original locations.
  56. Remove the LH valve cover.
    • Clean and inspect the mating surfaces and if necessary, install new gaskets.
      Fig 49: Removing LH Valve Cover
      G03947780Courtesy of FORD MOTOR CO.
    57. 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 which make leak paths.
    NOTE: There are several kinds of bolts used in fastening the valve cover. The bolts must be installed in their original locations.
  57. Remove the RH valve cover.
    • Clean and inspect the mating surfaces and if necessary. install new gaskets.
      Fig 50: Removing RH Valve Cover
      G03947781Courtesy of FORD MOTOR CO.
    58. NOTE: Use compressed air to remove any foreign material from the spark plug wells before removing the spark plugs.
  58. Remove the spark plugs.
  59. Remove the crankshaft pulley bolt. Using the special tool, remove the crankshaft pulley.
    Fig 51: Removing Crankshaft Pulley Using Special Tool
    G03919906Courtesy of FORD MOTOR CO.
  60. Using the special tool, remove the crankshaft front oil seal.
    Fig 52: Removing Crankshaft Front Seal Using Special Tool
    G03919889Courtesy of FORD MOTOR CO.
  61. Remove the 4 oil pan bolts.
    Fig 53: Locating (Four) Front Oil Pan Bolts
    G03885291Courtesy of FORD MOTOR CO.
    62. 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 which make leak paths.
    Fig 54: Removing Studs, Bolts And Engine Front Cover
    G03947785Courtesy of FORD MOTOR CO.
  62. Remove the studs, bolts and the engine front cover.
  63. Remove the front cover gaskets, clean and inspect the front cover sealing surfaces.
  64. Remove the crankshaft sensor ring from the crankshaft.
    Fig 55: Removing Crankshaft Sensor Ring From Crankshaft
    G03947786Courtesy of FORD MOTOR CO.
  65. Install the special tool between the valve spring coils to prevent valve stem seal damage.
    Fig 56: Installing Special Tool Between Valve Spring Coils
    G03947787Courtesy of FORD MOTOR CO.
    66. NOTE: Mark the followers for installation in their original locations.
    NOTE: Position the cam lobe away from the camshaft roller follower prior compressing the valve spring.
    Fig 57: Compressing Valve Spring
    G03947788Courtesy of FORD MOTOR CO.
  66. Using the special tool to compress the valve spring, remove the camshaft roller followers.
    67. CAUTION: If one or both of the tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.
  67. Remove the timing chain tensioning system from both timing chains.
    1. Remove the bolts.
    2. Remove the timing chain tensioners.
    3. Remove the timing chain tensioner arms.
      Fig 58: Removing Timing Chain Tensioner Arms
      G03947789Courtesy of FORD MOTOR CO.
  68. Remove the LH and the RH timing chains and the crankshaft sprocket.
    Fig 59: Removing LH And RH Timing Chains And Crankshaft Sprocket
    G03947790Courtesy of FORD MOTOR CO.
    69. NOTE: LH shown, RH similar.
    Fig 60: Removing Timing Chain Guides
    G03885314Courtesy of FORD MOTOR CO.
  69. Remove the bolts and both timing chain guides.
  70. Install the lifting handles on both ends of the cylinder head.
    Fig 61: Installing Lifting Handles On Both Ends Of Cylinder Head
    G04671899Courtesy of FORD MOTOR CO.
    71. NOTE: The hydraulic lash adjusters must be installed in their original locations. Record hydraulic lash adjuster locations.
    Fig 62: Identifying Hydraulic Lash Adjusters
    G03885650Courtesy of FORD MOTOR CO.
  71. Remove the hydraulic lash adjuster.
  72. Remove the nut and the coolant tube.
    Fig 63: Removing Nut And Coolant Tube
    G03947794Courtesy of FORD MOTOR CO.
    73. CAUTION: The cylinder head must be cool before removing it from the engine. Cylinder head warpage can result if a warm or hot cylinder head is removed.
    CAUTION: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.
    CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are torque-to-yield designed and cannot be reused.
    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: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
  73. Remove the bolts and the RH cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
      Fig 64: Locating Cylinder Head Bolts
      G03885651Courtesy of FORD MOTOR CO.
    74. CAUTION: The cylinder head must be cool before removing it from the engine. Cylinder head warpage can result if a warm or hot cylinder head is removed.
    CAUTION: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.
    CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are torque-to-yield designed and cannot be reused.
    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: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
  74. Remove the bolts and the LH cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
      Fig 65: Identifying LH Cylinder Head Bolts
      G03885652Courtesy of FORD MOTOR CO.
      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.
  75. Clean the cylinder head-to-cylinder block mating surfaces of both cylinder heads and the cylinder block.
    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.
    76. NOTE: Make sure all cylinder head surfaces are clear of any gasket material, RTV, oil and coolant. The cylinder head surface must be clean and dry before running a flatness check.
    NOTE: Use a straightedge that is calibrated by the manufacturer to be flat with 0.005 mm (0.0002 in) per running foot length. For example, if the straightedge is 61 cm (24 in) long, the machined edge must be flat with 0.010 mm (0.0004 in) from end to end.
    NOTE: LH is shown, RH is similar.
    Fig 66: Identifying Oil Pressure Feed Area Of Deck Face Surface
    G03885653Courtesy of FORD MOTOR CO.
  76. Support the cylinder heads on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge, paying particular attention to the oil pressure feed area. The cylinder heads must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area or scratches more than 0.0254 mm (0.001 in).
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