LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2000 >> Contour SE, 2.0 3, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 972 (Engine - 4.6L (2V) - F150 Pickup) >> Removal >> Cylinder Head

Cylinder Head

WARNING: This page is about a different car, the 2005 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOLS

G03885361
 Compressor, Valve Spring 303-452 (T97P-6565-AH)
G03885376
 Compressor Spacer, Valve Spring 303-382 (T91P-6565-AH)
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)
MATERIALS

Item Specification
Motorcraft Metal Surface Prep ZC-31 -
Silicone Gasket Remover ZC-30 -

    All cylinder heads 

  1. Remove the engine. For additional information, refer to ENGINE .
  2. Remove the 6 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 onto a suitable engine stand.
  5. Remove the 3 bolts and the RH engine support insulator.
    Fig 3: Identifying RH Engine Support Insulator Bolts
    G03933620Courtesy of FORD MOTOR CO.
    6. NOTE: LH shown, RH similar.
    Fig 4: Removing cylinder block drain plugs and drain the coolant into a suitable container
    G03885619Courtesy of FORD MOTOR CO.
  6. Remove the cylinder block drain plugs and drain the coolant into a suitable container.
    7. NOTE: LH shown, RH similar.
    Fig 5: Installing Cylinder Block Drain Plug
    G03885619Courtesy of FORD MOTOR CO.
  7. Install the cylinder block drain plugs.
    • Tighten to 24 Nm (18 lb-ft).
  8. Disconnect the engine oil pressure (EOP) sensor electrical connector.
    Fig 6: Disconnecting Engine Oil Pressure (EOP) Sensor Electrical Connector
    G03962630Courtesy of FORD MOTOR CO.
  9. Disconnect the knock sensor (KS) electrical connector and the wiring harness pin-type retainer.
    Fig 7: Disconnecting Knock Sensor (KS) Electrical Connector And Wiring Harness Pin-Type Retainer
    G03881828Courtesy of FORD MOTOR CO.
  10. Disconnect the camshaft position (CMP) sensor electrical connector.
    Fig 8: Disconnecting Camshaft Position (CMP) Sensor Electrical Connector
    G03885221Courtesy of FORD MOTOR CO.
  11. Disconnect the crankshaft position (CKP) sensor electrical connector.
    Fig 9: Disconnecting Crankshaft Position (CKP) Sensor Electrical Connector
    G04612789Courtesy of FORD MOTOR CO.
  12. Removing nut and the upper radiator hose bracket.
    Fig 10: Removing Nut And Upper Radiator Hose Bracket
    G03962421Courtesy of FORD MOTOR CO.
  13. Disconnect the LH radio ignition interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
    Fig 11: Disconnecting LH Radio Ignition Interference Capacitor And Cylinder Head Temperature (CHT) Sensor Electrical Connectors
    G03962635Courtesy of FORD MOTOR CO.
  14. Disconnect the RH radio ignition interference capacitor electrical connector.
    Fig 12: Disconnecting RH Radio Ignition Interference Capacitor Electrical Connector
    G03885622Courtesy of FORD MOTOR CO.
  15. Disconnect the engine wiring harness retainers from the valve cover studs and remove the electrical harness from the engine assembly.
    16. NOTE: RH shown, LH similar.
    Fig 13: Removing Nuts And 2 Radio Interference Capacitors
    G03906363Courtesy of FORD MOTOR CO.
  16. Remove the nuts and the 2 radio interference capacitors.
  17. Remove the bolt and the CMP sensor.
    Fig 14: Removing Bolt And CMP Sensor
    G03919989Courtesy of FORD MOTOR CO.
  18. Remove the bolt and the CKP sensor.
    Fig 15: Removing Bolt And CKP Sensor
    G03920231Courtesy of FORD MOTOR CO.
    19. 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. Use a plastic scraping tool to remove all traces of old sealant.
    NOTE: The bolts are part of the valve cover and should not be removed.
    NOTE: LH shown, RH similar.
    Fig 16: Removing LH Valve Cover
    G04612512Courtesy of FORD MOTOR CO.
  19. Remove the valve covers.
    • Fully loosen the bolts and remove the valve covers.
    • Clean the valve cover mating surface of the cylinder heads with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
  20. Remove the bolts, the coolant pump pulley and the accessory drive belt idler pulleys.
    Fig 17: Removing Bolts Coolant Pump Pulley And Accessory Drive Belt Idler Pulleys
    G03933688Courtesy of FORD MOTOR CO.
  21. Remove the bolts and the accessory drive belt tensioner.
    Fig 18: Removing Bolts And Accessory Drive Belt Tensioner
    G03920234Courtesy of FORD MOTOR CO.
  22. Remove the crankshaft pulley bolt and washer.
    • Discard the crankshaft pulley bolt.
  23. Using the special tool, remove the crankshaft pulley.
    Fig 19: Using Special Tool To Remove Crankshaft Pulley
    G03919906Courtesy of FORD MOTOR CO.
  24. Use the special tool to remove and discard the crankshaft front seal.
    Fig 20: Using Special Tool To Remove Crankshaft Front Seal
    G03919889Courtesy of FORD MOTOR CO.
  25. Remove the 4 front oil pan bolts.
    Fig 21: Removing Front Oil Pan Bolts
    G03885291Courtesy of FORD MOTOR CO.
    26. NOTE: Correct fastener location is essential for assembly procedure. Record the fastener location.
    Fig 22: Removing Fasteners
    G03962424Courtesy of FORD MOTOR CO.
  26. Remove the fasteners.
    27. 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. Use a plastic scraping tool to remove all traces of old sealant.
    Fig 23: Removing Engine Front Cover From Front Cover To Cylinder Block Dowel
    G03885295Courtesy of FORD MOTOR CO.
  27. Remove the engine front cover from the front cover to cylinder block dowel.
    • Remove the engine front cover gaskets.
    • Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    • Inspect the mating surfaces.
    28. CAUTION: Use care when removing the spark plugs.
    NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs.
  28. Remove the 8 spark plugs.
    29. NOTE: Camshaft roller follower is shown removed for clarity.
    Fig 24: Installing Special Tool Between Valve Spring Coils To Prevent Valve Stem Seal Damage
    G03962476Courtesy of FORD MOTOR CO.
  29. Install the special tool between the valve spring coils to prevent valve stem seal damage.
    30. NOTE: The camshaft roller followers must be reinstalled in their original locations. Record the camshaft roller follower locations.
    NOTE: Position the cam lobe away from the camshaft roller follower prior to removing each camshaft roller follower.
    Fig 25: Using Special Tool To Compress Valve Springs And Remove Camshaft Roller Followers
    G03962484Courtesy of FORD MOTOR CO.
  30. Using the special tool, compress the valve springs and remove the camshaft roller followers.
    31. NOTE: The camshaft roller followers must be reinstalled in their original locations.
  31. Repeat the previous 3 steps for each of the roller followers.
  32. Remove the crankshaft sensor ring from the crankshaft.
    Fig 26: Removing Crankshaft Sensor Ring From Crankshaft
    G04583449Courtesy of FORD MOTOR CO.
  33. Rotate the crankshaft until the timing mark on the RH camshaft sprocket is approximately at the 11 o'clock position and the timing mark on the LH camshaft sprocket is approximately at the 12 o'clock position.
    Fig 27: Identifying Timing Mark On RH Camshaft Sprocket
    G03962448Courtesy of FORD MOTOR CO.
    34. 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.
    Fig 28: Removing Timing Chain Tensioning System From Both Timing Chains
    G03962450Courtesy of FORD MOTOR CO.
  34. 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.
  35. Remove the timing chains and crankshaft sprocket.
    Fig 29: Removing Timing Chains And Crankshaft Sprocket
    G03885313Courtesy of FORD MOTOR CO.
  36. Remove the timing chain guides.
    1. Remove the bolts.
    2. Remove the LH timing chain guide.
    3. Remove the bolts.
    4. Remove the RH timing chain guide.
    Fig 30: Removing Timing Chain Guides
    G03962452Courtesy of FORD MOTOR CO.

    37. LH cylinder head 

  37. Remove the LH exhaust manifold.
    1. Remove the nuts.
    2. Remove the LH exhaust manifold.
    3. Remove and discard the LH exhaust manifold gasket.
    Fig 31: Removing LH Exhaust Manifold
    G03947756Courtesy of FORD MOTOR CO.
  38. Remove the bolt and the oil level indicator tube.
    Fig 32: Removing Bolt And Oil Level Indicator Tube
    G03906387Courtesy of FORD MOTOR CO.

    39. RH cylinder head 

  39. Remove the RH exhaust manifold.
    1. Remove the nuts.
    2. Remove the RH exhaust manifold.
    3. Remove and discard the RH exhaust manifold gasket.
    Fig 33: Removing RH Exhaust Manifold
    G03947754Courtesy of FORD MOTOR CO.
  40. Disconnect the coolant hoses from the heater outlet tube.
    Fig 34: Disconnecting Coolant Hoses From Heater Outlet Tube
    G03962838Courtesy of FORD MOTOR CO.
  41. Remove the heater outlet tube studs.
    Fig 35: Removing Heater Outlet Tube Studs
    G03962837Courtesy of FORD MOTOR CO.
  42. Remove the heater outlet tube and discard the O-ring seal.
    Fig 36: Removing Heater Outlet Tube
    G03905689Courtesy of FORD MOTOR CO.

    43. All cylinder heads 

  43. Install the special tools on both ends of the cylinder head being serviced.
    Fig 37: Installing Special Tools On Both Ends Of The Cylinder Head Being Serviced
    G04671899Courtesy of FORD MOTOR CO.
    44. 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 must be installed. They are tighten-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.
    NOTE: LH shown, RH similar.
    Fig 38: Removing Bolts And Cylinder Head
    G03885651Courtesy of FORD MOTOR CO.
  44. Remove the bolts and the cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
    45. 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.
  45. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head 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.
    46. 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 machine edge must be flat with 0.010 mm (0.0004 in) from end to end.
    NOTE: LH shown, RH similar.
    Fig 39: Identifying Oil Pressure Feed Area Of Deck Face Surface
    G03885653Courtesy of FORD MOTOR CO.
  46. Support the cylinder head 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 head 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).
scientia non olet · About LEMON Manuals