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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1153 (Engine -- 4.0L SOHC) >> In-Vehicle Repair >> Cylinder Head >> Removal

Cylinder Head: Removal

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.

    Both sides 

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING .
  2. Drain the engine cooling system. For additional information, refer to ENGINE COOLING .
  3. Remove the roller followers. For additional information, refer to CAMSHAFT ROLLER FOLLOWER .
  4. Remove the accessory drive belt tensioner. For additional information, refer to ACCESSORY DRIVE .

    5. RH side 

  5. Disconnect the generator electrical connections and disconnect the pushpin.
    Fig 1: Disconnecting Generator Electrical Connections
    G03946950Courtesy of FORD MOTOR CO.
  6. Remove the generator mounting bracket assembly.
    Fig 2: Removing Generator Mounting Bracket Assembly
    G03947001Courtesy of FORD MOTOR CO.
  7. Remove the heater hose from the thermostat housing.
    Fig 3: Removing Heater Hose From Thermostat Housing
    G03946952Courtesy of FORD MOTOR CO.
  8. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
    Fig 4: Disconnecting Engine Coolant Temperature Sensor Electrical Connector
    G03946953Courtesy of FORD MOTOR CO.
  9. Disconnect the upper radiator hose.
    Fig 5: Disconnecting Upper Radiator Hose
    G03914437Courtesy of FORD MOTOR CO.
  10. Position the coolant bypass hose clamp aside.
    Fig 6: Positioning Coolant Bypass Hose Clamp
    G03983779Courtesy of FORD MOTOR CO.
  11. Remove the bolts and the thermostat housing.
    Fig 7: Removing Bolts And Thermostat Housing
    G03946956Courtesy of FORD MOTOR CO.
  12. Remove the engine wiring harness bolts and position the engine wiring harness aside.
    Fig 8: Removing Engine Wiring Harness Bolts
    G03946995Courtesy of FORD MOTOR CO.
  13. Remove the engine ground strap.
    Fig 9: Removing Engine Ground Strap
    G03946958Courtesy of FORD MOTOR CO.

    14. LH side 

  14. Disconnect the radio ignition interference capacitor electrical connector.
    Fig 10: Disconnecting Radio Ignition Interference Capacitor Electrical Connector
    G03946959Courtesy of FORD MOTOR CO.
  15. Remove the bolts.
    Fig 11: Removing Bolts
    G03946960Courtesy of FORD MOTOR CO.
  16. Remove the bolts and position the accessory bracket aside.
    Fig 12: Identifying Accessory Bracket Bolts And Bracket
    G03913802Courtesy of FORD MOTOR CO.
  17. Remove the bolts and the coil bracket.
    Fig 13: Removing Bolts And Coil Bracket
    G03947447Courtesy of FORD MOTOR CO.
  18. Remove the oil level indicator tube.
    Fig 14: Locating Bolt And Oil Level Indicator Tube
    G03913929Courtesy of FORD MOTOR CO.

    19. Both sides 

    CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wires.
    Fig 15: Disconnecting Of Spark Plug Wires From Spark Plugs
    G03946991Courtesy of FORD MOTOR CO.
  19. Disconnect all of the spark plug wires from the spark plugs.
  20. Remove the engine noise shield.
    Fig 16: Removing Engine Noise Shield
    G03946993Courtesy of FORD MOTOR CO.
    21. NOTE: LH side shown, RH side similar.
    Fig 17: Locating Catalytic Converter-To-Manifold Nuts
    G03946966Courtesy of FORD MOTOR CO.
  21. Remove the 4 catalytic converter-to-manifold nuts.
  22. Remove both of the exhaust manifolds and gaskets.
    • Discard the gaskets and the retaining nuts.
      Fig 18: Removing Both Of Exhaust Manifolds And Gaskets
      G03946967Courtesy of FORD MOTOR CO.

    23. RH side 

  23. Remove the RH side hydraulic chain tensioner.
    Fig 19: Removing RH Side Hydraulic Chain Tensioner
    G03947014Courtesy of FORD MOTOR CO.
  24. Install the special tools.
    • Tighten to 10 Nm (89 lb-in).
      Fig 20: Installing Special Tools
      G03946900Courtesy of FORD MOTOR CO.
  25. Using the special tool with the Camshaft Sprocket Nut Socket 303-565, remove the RH camshaft bolt.
    Fig 21: Removing RH Camshaft Bolt Using Special Tool
    G03946901Courtesy of FORD MOTOR CO.
  26. Remove the RH side cassette bolt.
    Fig 22: Removing RH Side Cassette Bolt
    G03983797Courtesy of FORD MOTOR CO.
    27. CAUTION: Remove the camshaft sprocket from the timing chain to gain clearance to remove the cylinder head.
    NOTE: Hold the timing chain and cassette with a rubber band to aid in removal and to prevent the timing chain from falling into the cylinder block.
    Fig 23: Removing RH Camshaft Sprocket From Timing Chain
    G03946977Courtesy of FORD MOTOR CO.
  27. Remove the RH camshaft sprocket from the timing chain. Install a rubber band around the cassette and the timing chain.

    28. LH side 

  28. Remove the LH side hydraulic chain tensioner.
    Fig 24: Identifying LH Camshaft Tensioner
    G03913851Courtesy of FORD MOTOR CO.
  29. Install the special tools.
    • Tighten the top clamp bolts to 10 Nm (89 lb-in).
      Fig 25: Identifying Special Holding Tool
      G03946909Courtesy of FORD MOTOR CO.
  30. Remove the LH side camshaft sprocket bolt.
    Fig 26: Removing LH Side Camshaft Sprocket Bolt
    G03913853Courtesy of FORD MOTOR CO.
  31. Remove the LH side cassette bolt.
    Fig 27: Identifying LH Cassette Upper Bolt
    G03913945Courtesy of FORD MOTOR CO.
    32. CAUTION: Remove the camshaft sprocket from the timing chain to gain clearance to remove the cylinder head.
    NOTE: Hold the timing chain and cassette with a rubber band to aid in removal and to prevent the timing chain from falling into the cylinder block.
    Fig 28: Removing LH Camshaft Sprocket From Timing Chain
    G03946977Courtesy of FORD MOTOR CO.
  32. Remove the LH camshaft sprocket from the timing chain. Install a rubber band around the cassette and the timing chain.

    33. Both sides 

    CAUTION: To avoid damage to the timing chain cassette an assistant will be required to help lift the cylinder head from the vehicle.
    CAUTION: On the RH side, when lifting the cylinder head be careful to avoid contacting the A/C tube.
    NOTE: New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.
  33. Remove the cylinder heads.
    • Remove the cylinder head bolts in the sequence shown in Fig 29. Discard all bolts.
    • Remove and discard the head gasket.
      Fig 29: Removing Cylinder Head Bolts In Sequence
      G03946978Courtesy of FORD MOTOR CO.
    34. 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.
  34. Clean and inspect the mating surfaces.
  35. Inspect the cylinder head and the cylinder block for flatness. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
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