LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1263 (Engine - 3.9) >> Removal >> Cylinder Heads

Cylinder Heads

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

G03889585
 Strap Wrench 303-D055
G03886657
 Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D)
G03898751
 Remover, Oil Seal 303-409 (T92C-6700-CH)
G03996700
 Alignment Gauge, Crankshaft 303-645
G03996387
 Aligner, Camshaft 303-530
CYLINDER HEADS MATERIAL SPECIFICATION

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

    Both sides 

  1. Remove the engine. For additional information, refer to ENGINE  in this article .
  2. Install the engine on a suitable engine stand.
  3. Remove the engine block plug to drain the engine coolant.
  4. Disconnect the oil pressure and oil temperature sensor electrical connectors.
    Fig 1: Locating Oil Pressure And Oil Temperature Sensor Electrical Connectors
    G03996596Courtesy of FORD MOTOR CO.
  5. Remove and discard the oil filter.
    Fig 2: Removing Oil Filter
    G03996432Courtesy of FORD MOTOR CO.
    6. CAUTION: A new oil cooler must be installed or severe damage to the engine can occur.
  6. Remove the bolt and oil cooler.
    • Discard the oil cooler and gasket.
  7. Remove the bolt and the accessory drive belt tensioner.
    Fig 3: Locating Bolt And Accessory Drive Belt Tensioner
    G03996433Courtesy of FORD MOTOR CO.
  8. Remove the bolt and the accessory drive belt idler pulley.
    Fig 4: Removing Bolt Accessory Drive Belt Idler Pulley
    G03996434Courtesy of FORD MOTOR CO.
  9. Remove the 3 bolts and the coolant pump pulley.
    Fig 5: Removing Coolant Pump Pulley Bolts
    G03996435Courtesy of FORD MOTOR CO.
    10. NOTE: Hold the crankshaft pulley with the special tool while removing the bolt and washer.
    Fig 6: Identifying Special Tool To Hold Pulley
    G03996436Courtesy of FORD MOTOR CO.
  10. Remove and discard the bolt and washer.
  11. Using the special tool, remove the crankshaft damper.
    Fig 7: Removing Crankshaft Damper
    G03996437Courtesy of FORD MOTOR CO.
  12. Using the special tool, remove and discard the front crankshaft seal.
    Fig 8: Removing Front Crankshaft Seal
    G03996310Courtesy of FORD MOTOR CO.
    13. NOTE: LH shown, RH similar.
  13. Remove the LH and RH ignition coil covers.
  14. Remove all silicone sealer and residue from the ignition coil covers.
    Fig 9: Removing All Silicone Sealer
    G03996439Courtesy of FORD MOTOR CO.
    15. NOTE: LH shown, RH similar.
    Fig 10: Removing All Silicone Sealer From Ignition Coil Wiring Harness
    G03996440Courtesy of FORD MOTOR CO.
  15. Remove all silicone sealer and residue from the valve cover surface and ignition coil wiring harness.
  16. Disconnect the 8 ignition coil electrical connectors.
    Fig 11: Identifying Ignition Coil Electrical Connectors
    G03996441Courtesy of FORD MOTOR CO.
  17. Disconnect the throttle position (TP) sensor electrical connector.
    Fig 12: Identifying Throttle Position (TP) Sensor Electrical Connector
    G03996442Courtesy of FORD MOTOR CO.
  18. Disconnect the fuel pressure sensor electrical connector.
    Fig 13: Locating Fuel Pressure Sensor Electrical Connector
    G03996443Courtesy of FORD MOTOR CO.
  19. Disconnect the electronic throttle body electrical connector.
    Fig 14: Locating Electronic Throttle Body Electrical Connector
    G03996444Courtesy of FORD MOTOR CO.
  20. Disconnect the evaporative emissions (EVAP) tube.
    Fig 15: Locating Evaporative Emissions Tube
    G03996445Courtesy of FORD MOTOR CO.
  21. Disconnect the fuel rail temperature sensor electrical connector.
    Fig 16: Locating Fuel Rail Temperature Sensor Electrical Connector
    G03996446Courtesy of FORD MOTOR CO.
  22. Disconnect the exhaust gas recirculation (EGR) system module electrical connector.
    Fig 17: Disconnecting Exhaust Gas Recirculation System Module Electrical Connector
    G03996447Courtesy of FORD MOTOR CO.
  23. Disconnect the coolant vent hose from the coolant outlet.
    • Remove the coolant vent hose.
    Fig 18: Identifying Coolant Vent Hose To Coolant Outlet
    G03996448Courtesy of FORD MOTOR CO.
  24. Remove the vacuum harness.
    Fig 19: Identifying Vacuum Harness
    G03996449Courtesy of FORD MOTOR CO.
    25. NOTE: LH shown, RH similar.
    Fig 20: Identifying Engine Wiring Harness
    G03996450Courtesy of FORD MOTOR CO.
  25. Disconnect the engine wiring harness retainers from the engine appearance cover support brackets.
  26. Detach the vacuum hose retainers from the LH engine appearance cover support bracket.
    Fig 21: Locating Vacuum Hose Retainers
    G03996451Courtesy of FORD MOTOR CO.
    27. NOTE: RH shown, LH similar.
    Fig 22: Identifying Engine Appearance Cover Brackets And Nuts
    G03996452Courtesy of FORD MOTOR CO.
  27. Remove the 4 nuts and the 2 engine appearance cover brackets.
    28. NOTE: LH shown, RH similar.
    Fig 23: Locating Fuel Injector And Radio Interference Capacitor Electrical Connectors
    G03996269Courtesy of FORD MOTOR CO.
  28. Disconnect the 8 fuel injector and the 2 radio interference capacitor electrical connectors.
  29. Disconnect the knock sensor (KS) and camshaft position (CMP) senor electrical connectors.
    • Detach the pin-type retainers.
    Fig 24: Locating KS And CMP Sensor Electrical Connectors
    G03996454Courtesy of FORD MOTOR CO.
    30. NOTE: RH shown, LH similar.
    Fig 25: Locating VCT Sensor Electrical Connectors
    G03996455Courtesy of FORD MOTOR CO.
  30. Disconnect the 2 variable cam timing (VCT) sensor electrical connectors.
  31. Remove the 5 bolts and the power steering bracket.
    Fig 26: Identifying Power Steering Bracket And Bolts
    G03996456Courtesy of FORD MOTOR CO.
  32. Disconnect the wiring harness retainers from the LH valve cover.
    Fig 27: Locating Wiring Harness Retainers At LH Valve Cover
    G03996457Courtesy of FORD MOTOR CO.
  33. Detach the wiring harness from the engine front cover.
    Fig 28: Locating Wiring Harness At Front Cover
    G03996458Courtesy of FORD MOTOR CO.
  34. Disconnect the crankshaft position (CKP) sensor electrical connector and wiring harness retainers.
    Fig 29: Identifying CKP Sensor Electrical Connector And Wiring Harness
    G03996459Courtesy of FORD MOTOR CO.
  35. Disconnect the wiring harness retainers from the RH valve cover.
    Fig 30: Locating Wiring Harness Retainers At RH Valve Cover
    G03996622Courtesy of FORD MOTOR CO.
  36. Disconnect the generator electrical connector and wiring harness retainers.
    Fig 31: Identifying Generator Electrical Connector, Wiring Harness And Retainers
    G03996461Courtesy of FORD MOTOR CO.
  37. Remove the heated oxygen sensor (HO2S) electrical connectors from the brackets.
    Fig 32: Locating Heated Oxygen Sensor (HO2S) Electrical Connector Brackets
    G03996462Courtesy of FORD MOTOR CO.
  38. Remove the engine wiring harness from the engine.
  39. Remove the nut and the oil level indicator tube.
    • Discard the O-ring seal.
    Fig 33: Locating Nut And Oil Level Indicator Tube
    G03996463Courtesy of FORD MOTOR CO.
  40. Remove the 8 bolts and the 8 ignition coils.
    Fig 34: Identifying Bolts And Ignition Coils
    G03996464Courtesy of FORD MOTOR CO.
  41. Remove the crankcase vent tube.
    Fig 35: Identifying Crankcase Vent Tube
    G03996465Courtesy of FORD MOTOR CO.
  42. Disconnect the exhaust manifold tube at the EGR system module.
    Fig 36: Disconnecting Exhaust Manifold Tube EGR System Module
    G03996466Courtesy of FORD MOTOR CO.
    43. NOTE: RH shown, LH similar.
    Fig 37: Identifying Radio Interference Ignition Capacitors Mounting Bracket And Nuts
    G03996467Courtesy of FORD MOTOR CO.
  43. Remove the 2 nuts and the radio interference capacitors.
  44. Disconnect the throttle body heater hoses.
    Fig 38: Locating Throttle Body Coolant Hoses
    G03996468Courtesy of FORD MOTOR CO.
  45. Remove the 4 bolts and the coolant bypass housing.
    • Discard the O-ring seals.
    Fig 39: Removing Coolant Bypass Housing Bolts
    G03996469Courtesy of FORD MOTOR CO.
  46. Remove the 4 bolts and the throttle body adapter.
    • Discard the gasket.
    Fig 40: Removing Throttle Body Adapter Bolts
    G03996470Courtesy of FORD MOTOR CO.
  47. Remove the 7 bolts and 3 studs in the sequence shown.
    • Remove the intake manifold.
    • Discard the gaskets.
    Fig 41: Identifying Intake Manifold Bolts Loosening/Tightening Sequence
    G03996271Courtesy of FORD MOTOR CO.
    48. 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 clean the surfaces.
    Fig 42: Identifying Sealing Surfaces
    G03996472Courtesy of FORD MOTOR CO.
  48. Clean the sealing surfaces.
  49. Remove the bolts in the sequence shown and remove the RH valve cover.
    • Discard the gasket.
    Fig 43: RH Valve Cover Bolt Removal Sequence
    G03996473Courtesy of FORD MOTOR CO.
  50. Remove the bolts in the sequence shown and remove the LH valve cover.
    Fig 44: Valve Cover Bolt Removal Sequence
    G03996474Courtesy 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. Use a plastic scraping tool to clean the surfaces.
    Fig 45: Removing Gaskets And All Silicone Sealer
    G03996475Courtesy of FORD MOTOR CO.
  51. Remove the gaskets and all silicone sealer. Clean the mating surfaces with silicone gasket remover.

    52. RH side 

  52. Remove the 2 nuts and the EGR tube.
    • Discard the gasket.
    Fig 46: Locating Nuts And EGR Tube
    G03996476Courtesy of FORD MOTOR CO.
  53. Remove the 4 bolts and the RH exhaust manifold heat shield.
    Fig 47: Removing RH Exhaust Manifold Heat Shield Bolts
    G03996477Courtesy of FORD MOTOR CO.
  54. Remove the nuts and the RH exhaust manifold.
    • Discard the nuts.
    Fig 48: Removing RH Exhaust Manifold Nuts
    G03996478Courtesy of FORD MOTOR CO.
  55. Remove the RH exhaust manifold heat shield stud bolt.
    • Discard the exhaust manifold gasket.
    Fig 49: Removing RH Exhaust Manifold Heat Shield Stud Bolt
    G03996479Courtesy of FORD MOTOR CO.
  56. Remove the 8 RH exhaust manifold studs and discard.
  57. Clean and inspect the RH exhaust manifold. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .

    58. LH side 

  58. Remove the 4 bolts and the LH exhaust manifold heat shield.
    Fig 50: Identifying Bolts And LH Exhaust Manifold Heat Shield
    G03996480Courtesy of FORD MOTOR CO.
  59. Remove the nuts and the LH exhaust manifold.
    • Discard the nuts.
    Fig 51: Removing Nuts LH Exhaust Manifold
    G03996481Courtesy of FORD MOTOR CO.
  60. Remove the LH exhaust manifold heat shield stud bolt.
    • Discard the exhaust manifold gasket.
    Fig 52: Locating LH Exhaust Manifold Heat Shield Stud Bolt
    G03996482Courtesy of FORD MOTOR CO.
  61. Remove the 8 LH exhaust manifold studs and discard.
  62. Clean the inspect the LH exhaust manifold. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .

    63. Both sides 

  63. Remove the engine front cover bolts in the sequence shown.
    • Remove the engine front cover.
    • Discard the gaskets.
    Fig 53: Removing Engine Front Cover
    G03996483Courtesy of FORD MOTOR CO.
    64. 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 sealant.
    Fig 54: Cleaning Sealing Surfaces
    G03996328Courtesy of FORD MOTOR CO.
  64. Clean the sealing surfaces.
  65. Remove the RH and LH variable cam timing (VCT) bush carriers.
    Fig 55: Identifying RH And LH Variable Cam Timing Bush Carriers, Bolts & Nuts
    G03996382Courtesy of FORD MOTOR CO.
  66. Remove the bolt and the CKP sensor.
    Fig 56: Identifying Bolt And CKP Sensor
    G03996486Courtesy of FORD MOTOR CO.
    67. NOTE: There is one window on the ignition pulse wheel that is unique to accept the special tool.
    Fig 57: Identifying Special Tool
    G03996341Courtesy of FORD MOTOR CO.
  67. Install the special tool.
    • Turn the crankshaft to 45 degrees ATDC. The crankshaft keyway will be in the 6 o'clock position.
    • Install the special tool.
  68. Make sure the flats of the camshaft are facing upward. If not, repeat the previous step.
    Fig 58: Checking Flats Of Camshaft Are Facing Upward
    G03996342Courtesy of FORD MOTOR CO.
    69. CAUTION: The flats on the camshaft must completely contact the special service tool or damage to the camshafts can occur. Slowly draw the special tool down evenly until it is fully seated on the camshaft flats.
    Fig 59: Identifying Special Tool On RH Cylinder Head
    G03996343Courtesy of FORD MOTOR CO.
  69. Install the special tool on the RH cylinder head.
    70. CAUTION: An open-end wrench must be used on the hex area of the camshaft or damage to the head will occur.
    Fig 60: Removing Exhaust Camshaft Sprocket Bolt
    G03996344Courtesy of FORD MOTOR CO.
  70. Remove and discard the exhaust camshaft sprocket bolt.
    71. CAUTION: An open-end wrench must be used on the hex area of the camshaft or damage to the head will occur.
    Fig 61: Removing VCT Unit Bolt
    G03996345Courtesy of FORD MOTOR CO.
  71. Remove and discard the VCT unit bolt.
  72. Remove the RH timing chain tensioner.
    • Push the lever down and install a drill rod to lock the piston.
    • Remove the 2 bolts and the tensioner.
    Fig 62: Removing RH Timing Chain Tensioner Bolts
    G03996346Courtesy of FORD MOTOR CO.
  73. Remove the bolt and the RH tensioner arm.
    Fig 63: Identifying RH Timing Chain Tensioner Arm
    G03996347Courtesy of FORD MOTOR CO.
  74. Remove the bolt and the RH timing chain guide.
    Fig 64: Identifying Bolt And RH Timing Chain Guide
    G03996377Courtesy of FORD MOTOR CO.
  75. Remove the RH primary timing chain.
    Fig 65: Identifying RH Primary Timing Chain
    G03996349Courtesy of FORD MOTOR CO.
  76. Remove the special tool from the RH cylinder head.
    Fig 66: Identifying Special Tool On RH Cylinder Head
    G03996343Courtesy of FORD MOTOR CO.
    77. CAUTION: The flats on the camshaft must completely contact the special service tool or damage to the camshafts can occur. Slowly draw the special tool down evenly until it is fully seated on the camshaft flats.
    Fig 67: Identifying Special Tool On LH Cylinder Head
    G03996351Courtesy of FORD MOTOR CO.
  77. Install the special tool on the LH cylinder head.
    78. CAUTION: An open-end wrench must be used on the hex area of the camshaft or damage to the cylinder head will occur.
    Fig 68: Removing LH VCT Unit Bolt
    G03996352Courtesy of FORD MOTOR CO.
  78. Remove and discard the LH VCT unit bolt and the exhaust camshaft sprocket bolt.
  79. Remove the LH timing chain tensioner.
    • Push the lever down and install a drill rod to lock the piston.
    • Remove the 2 bolts and the tensioner.
    Fig 69: Removing Bolts Tensioner
    G03996353Courtesy of FORD MOTOR CO.
  80. Remove the nut and the LH tensioner arm.
    Fig 70: Identifying LH Timing Chain Tensioner Arm And Nut
    G03996354Courtesy of FORD MOTOR CO.
  81. Remove the bolt and the LH timing chain guide.
    Fig 71: Identifying LH Timing Chain Guide And Bolt
    G03996355Courtesy of FORD MOTOR CO.
  82. Remove the LH primary timing chain.
    Fig 72: Identifying LH Timing Chain And Crankshaft Gear
    G03996356Courtesy of FORD MOTOR CO.
  83. Remove the crankshaft sprocket.
  84. Collapse the LH secondary timing chain tensioner and install a pin to lock the piston.
    Fig 73: Locating Locking Pin For LH Secondary Timing Chain Tensioner
    G03996359Courtesy of FORD MOTOR CO.
  85. Remove the LH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.
    Fig 74: Identifying LH VCT Unit, Exhaust Camshaft Sprocket And Timing Chain
    G03996360Courtesy of FORD MOTOR CO.
  86. Remove the 2 bolts and the LH secondary timing chain tensioner.
  87. Collapse the RH secondary timing chain tensioner and install a pin to lock the piston.
    Fig 75: Locating Locking Pin For RH Secondary Timing Chain Tensioner
    G03996357Courtesy of FORD MOTOR CO.
  88. Remove the RH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.
    Fig 76: Identifying RH VCT Unit
    G03996358Courtesy of FORD MOTOR CO.
  89. Remove the 2 bolts and the RH secondary timing chain tensioner.
  90. Remove the special tool.
    Fig 77: Removing Special Tool
    G03996388Courtesy of FORD MOTOR CO.

    91. LH side 

    CAUTION: Record the camshaft bearing cap locations. The camshaft bearing caps are positional and must be installed in their original locations and orientation or engine damage can occur.
    Fig 78: Removing LH Camshaft Bearing Caps
    G03996508Courtesy of FORD MOTOR CO.
  91. Remove the LH camshaft bearing caps.
    • Remove the bolts.
    • Remove the LH camshaft bearing caps.
  92. Remove the LH camshafts.
    Fig 79: Identifying LH Camshafts On Camshaft Journals
    G03996392Courtesy of FORD MOTOR CO.
    93. CAUTION: Do not use any means of marking the shims other than a permanent-type marker. Any scratches or paint on the shims can result in incorrect lash adjustments and severe engine damage.
    CAUTION: Record the shim and bucket tappet location. The shim and bucket tappet are positional and if installed in the incorrect location, engine damage can occur.
  93. Record the location of the valve tappets.
    • Remove the valve tappets.
    94. 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 tighten-to-yield designed and cannot be reused.
    CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
    Fig 80: Identifying RH Cylinder Head End Bolts
    G03996510Courtesy of FORD MOTOR CO.
  94. Remove the LH cylinder head end bolts.
    • Discard the bolts.
  95. Remove and discard the bolts from LH cylinder head in the sequence shown.
    • Remove the cylinder head.
    • Discard the gasket.
    Fig 81: Removing Bolts From LH Cylinder Head
    G03996511Courtesy of FORD MOTOR CO.

    96. RH side 

    CAUTION: Record the camshaft bearing cap locations. The camshaft bearing caps are positional and must be installed in their original locations and orientation or engine damage can occur.
    Fig 82: Locating RH Camshafts On Camshaft Journals
    G03996512Courtesy of FORD MOTOR CO.
  96. Remove the RH camshaft bearing caps.
    • Remove the bolts.
    • Remove the RH camshaft bearing caps.
  97. Remove the RH camshafts.
    Fig 83: Removing RH Camshafts
    G03996513Courtesy of FORD MOTOR CO.
    98. CAUTION: Do not use any means of marking the shims other than a permanent-type marker. Any scratches or paint on the shims can result in incorrect lash adjustments and severe engine damage.
    CAUTION: Record the shim and bucket tappet location. The shim and bucket tappet are positional and if installed in the incorrect location, engine damage can occur.
  98. Record the location of the valve tappets.
    • Remove the valve tappets.
    99. 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 tighten-to-yield designed and cannot be reused.
    CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
    Fig 84: Identifying RH Cylinder Head End Bolts
    G03996510Courtesy of FORD MOTOR CO.
  99. Remove the RH cylinder head end bolts.
    • Discard the bolts.
  100. Remove and discard the bolts from the RH cylinder head in the sequence shown.
    • Remove the cylinder head.
    • Discard the gasket.
    Fig 85: Removing Cylinder Head
    G03996511Courtesy of FORD MOTOR CO.

    101. Both sides 

    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 sealant.
    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.
  101. Clean the cylinder head-to-cylinder block mating surfaces of both the 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.
    102. NOTE: The straightedge used must be flat within 0.0051 mm (0.0002 in) per foot of tool length.
  102. 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).
scientia non olet · About LEMON Manuals