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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1558 (Engine - 5.4L (3V) - F250 & F350) >> Removal >> Cylinder Head

Cylinder Head

WARNING: This page is about a different car, the 2006 Ford Pickup and 2006 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOLS REFERENCE

G04647193
 Remover/Installer, Cylinder Head
303-572 (T97T-6000-A)
G04647194
 Locking Tool, Camshaft Phaser Sprocket
303-1046
G04647195
 Compressor, Valve Spring
303-1039
G04647196
 Remover, Crankshaft Vibration Damper
303-009 (T58P-6316-D)
G04647197
 Remover, Crankshaft Front Seal
303-107 (T74P-6700-A)
G04647198
 Modular Engine Lift Bracket
303-F047 (014-00073) or equivalent
MATERIAL SPECIFICATIONS

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

    All cylinder heads 

  1. Remove the engine. For additional information, refer to ENGINE .
    2. NOTE: Flexplate shown, flywheel similar.
    Fig 1: Locating Flexplate Bolts
    G03885481Courtesy of FORD MOTOR CO.
  2. Remove the bolts and the flexplate or flywheel.
  3. Install the engine onto a suitable engine stand.
  4. Remove the special tool.
    Fig 2: Identifying Special Tool (303-F047)
    G03920205Courtesy of FORD MOTOR CO.
  5. Remove the 4 bolts and the RH engine support insulator.
    Fig 3: Locating RH Engine Support Insulator Bolts
    G04647201Courtesy of FORD MOTOR CO.
  6. Remove the 4 bolts and the RH engine support insulator bracket.
    Fig 4: Locating RH Engine Support Insulator Bracket Bolts
    G04647202Courtesy of FORD MOTOR CO.
    7. NOTE: LH shown, RH similar.
    Fig 5: Locating Cylinder Block Drain Plug
    G03885619Courtesy of FORD MOTOR CO.
  7. Remove the cylinder block drain plugs and drain the coolant into a suitable container.
    8. NOTE: LH shown, RH similar.
  8. Install the cylinder block drain plugs.
    • Tighten to 24 Nm (18 lb-ft).
      Fig 6: Locating Cylinder Block Drain Plug
      G03885619Courtesy of FORD MOTOR CO.
  9. Disconnect the RH camshaft position (CMP) sensor electrical connector.
    Fig 7: Identifying RH CMP Sensor Electrical Connector
    G03919909Courtesy of FORD MOTOR CO.
  10. Remove the stud bolt and the RH radio ignition interference capacitor.
    Fig 8: Identifying RH Radio Ignition Interference Capacitor Stud Bolt
    G03920219Courtesy of FORD MOTOR CO.
  11. Disconnect the RH variable camshaft timing (VCT) solenoid electrical connector.
    Fig 9: Locating Camshaft Timing (VCT) Solenoid Electrical Connectors
    G03920220Courtesy of FORD MOTOR CO.
  12. Disconnect the 2 engine wiring harness retainers from the RH valve cover studs.
    Fig 10: Locating Engine Wiring Harness Retainers At RH Valve Cover
    G03920221Courtesy of FORD MOTOR CO.
  13. Disconnect the electrical connector retainer from the coolant tube.
    Fig 11: Locating Electrical Connector Retainer At Coolant Tube Support Bracket
    G03919850Courtesy of FORD MOTOR CO.
  14. Disconnect the 4 RH ignition coil electrical connectors.
    Fig 12: Locating Ignition Coil Electrical Connectors
    G03920223Courtesy of FORD MOTOR CO.
  15. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
    Fig 13: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector
    G03920224Courtesy of FORD MOTOR CO.
  16. Remove the stud bolt and the LH radio ignition interference capacitor.
    Fig 14: Identifying LH Radio Ignition Interference Capacitor And Stud Bolt
    G03920225Courtesy of FORD MOTOR CO.
    17. NOTE: LH shown, RH similar.
    Fig 15: Identifying Ignition Coils And Bolts
    G03920226Courtesy of FORD MOTOR CO.
  17. Remove the 8 bolts and the 8 ignition coils.
  18. Remove the engine wiring harness from the engine assembly.
  19. Remove the rear oil level indicator tube bolt.
    Fig 16: Locating Rear Oil Level Indicator Tube Bolt
    G03920295Courtesy of FORD MOTOR CO.
  20. Remove the bolt and the oil level indicator tube.
    • Discard the O-ring seal.
      Fig 17: Locating Front Oil Level Indicator Tube Bolt
      G03920296Courtesy of FORD MOTOR CO.
  21. Remove the bolt and the RH CMP sensor.
    Fig 18: Locating Camshaft (CMP) Sensor Bolt
    G03920013Courtesy of FORD MOTOR CO.
  22. Remove the bolt and the LH CMP sensor.
    Fig 19: Locating Bolt And LH CMP Sensor
    G03919989Courtesy of FORD MOTOR CO.
  23. Remove the bolt and the CKP sensor.
    Fig 20: Locating Crankshaft Position (CKP) Sensor Bolt
    G03920231Courtesy of FORD MOTOR CO.
    24. 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.
    CAUTION: When removing the valve cover, make sure to avoid damaging the VCT solenoid.
    NOTE: The fasteners are part of the valve cover and should not be removed.
    NOTE: LH shown, RH similar.
  24. Remove the valve covers.
    • Fully loosen the fasteners and remove the valve cover.
    • Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    • Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
      Fig 21: Identifying Valve Cover Nuts
      G04647219Courtesy of FORD MOTOR CO.
  25. Remove the bolts, coolant pump pulley and accessory drive belt idler pulley.
    Fig 22: Identifying Coolant Pump Pulley Bolts And Idler Pulley Bolt
    G03920233Courtesy of FORD MOTOR CO.
  26. Remove the bolts and the accessory drive belt tensioner.
    Fig 23: Identifying Accessory Drive Belt Tensioner Bolts
    G03920234Courtesy of FORD MOTOR CO.
  27. Remove and discard the crankshaft pulley bolt. Using the special tool, remove the crankshaft pulley.
    Fig 24: Removing Crankshaft Pulley Using Special Tool
    G03919906Courtesy of FORD MOTOR CO.
  28. Using the special tool, remove and discard the crankshaft front seal.
    Fig 25: Removing Crankshaft Front Seal Using Special Tool
    G03919889Courtesy of FORD MOTOR CO.
    29. NOTE: Correct fastener location is essential for assembly procedure. Record fastener location.
    Fig 26: Locating Fasteners
    G04647224Courtesy of FORD MOTOR CO.
  29. Remove the fasteners.
  30. Remove the 4 front oil pan bolts.
    Fig 27: Locating Oil Pan Bolts-To-Front Cover
    G03885636Courtesy of FORD MOTOR CO.
  31. Remove the engine front cover from the cylinder block.
    Fig 28: Locating Engine Front Cover
    G03885740Courtesy of FORD MOTOR CO.
  32. Remove the crankshaft sensor ring from the crankshaft.
    Fig 29: View Of Crankshaft Sensor Ring At Crankshaft
    G04583449Courtesy of FORD MOTOR CO.
  33. Position the crankshaft keyway at the 12 o'clock position.
    Fig 30: Positioning Crankshaft Keyway At 12 O'Clock Position
    G03919943Courtesy of FORD MOTOR CO.
    34. NOTE: If the camshaft lobes are not exactly positioned as shown, the crankshaft will require 1 full additional rotation to 12 o'clock.
    Fig 31: Identifying Camshaft Lobe Position
    G03919944Courtesy of FORD MOTOR CO.
  34. The No. 1 cylinder camshaft exhaust lobe must be coming up on the exhaust stroke. Verify by noting the position of the 2 intake camshaft lobes and the exhaust lobe on the No. 1 cylinder.
    35. CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original locations.
    Fig 32: Identifying RH Cylinder Head Camshaft Roller Followers And Bolts
    G03919945Courtesy of FORD MOTOR CO.
  35. Remove only the 3 camshaft roller followers shown in the illustration from the RH cylinder head.
    36. CAUTION: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder.
    NOTE: It may be necessary to push the valve down while compressing the spring.
    Fig 33: Identifying Special Tool For Removing/Installing Camshaft Roller Followers
    G03919946Courtesy of FORD MOTOR CO.
  36. Using the special tool, remove the 3 designated camshaft roller followers in the previous step from the RH cylinder head.
    37. CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original locations.
    Fig 34: Locating LH Cylinder Head Camshaft Roller Followers And Bolts
    G03919947Courtesy of FORD MOTOR CO.
  37. Remove only the 3 camshaft roller followers shown in the illustration from the LH cylinder head.
    38. CAUTION: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder.
    NOTE: It may be necessary to push the valve down while compressing the spring.
    Fig 35: Compressing Spring Using Special Tool
    G03919948Courtesy of FORD MOTOR CO.
  38. Using the special tool, remove the 3 designated camshaft roller followers in the previous step from the LH cylinder head.
    39. CAUTION: The crankshaft cannot be moved past the 6 o'clock position once set.
    Fig 36: Crankshaft Positioned With Keyway At 6 O'clock Position
    G03919949Courtesy of FORD MOTOR CO.
  39. Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.
    40. 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 37: Identifying LH Timing Chain Tensioner & Tensioner Arm
    G03919950Courtesy of FORD MOTOR CO.
  40. Remove the bolts, the LH timing chain tensioner and tensioner arm.
    41. 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 38: Identifying RH Timing Chain Tensioner, Tensioner Arm And Bolts
    G03919951Courtesy of FORD MOTOR CO.
  41. Remove the bolts, the RH timing chain tensioner and tensioner arm.
  42. Remove the RH and LH timing chains and the crankshaft sprocket.
    • Remove the RH timing chain from the camshaft sprocket.
    • Remove the RH timing chain from the crankshaft sprocket.
    • Remove the LH timing chain from the camshaft sprocket.
    • Remove the LH timing chain and crankshaft sprocket.
      Fig 39: Identifying RH/LH Timing Chains
      G03919952Courtesy of FORD MOTOR CO.
    43. NOTE: RH shown, LH similar.
  43. Remove the LH and RH timing chain guides.
    • Remove the bolts.
    • Remove both timing chain guides.
      Fig 40: Identifying Timing Chain Guide And Mounting Bolts
      G03919953Courtesy of FORD MOTOR CO.
    44. CAUTION: Damage to the VCT phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.
    CAUTION: Only use hand tools to remove the VCT phaser sprocket assembly or damage may occur to the camshaft or VCT phaser sprocket.
  44. Using the special tool, remove the bolt and the RH VCT phaser sprocket assembly.
    • Discard the VCT phaser sprocket bolt.
      Fig 41: Identifying VCT Phaser Sprocket Bolt And Holder Tool
      G03919954Courtesy of FORD MOTOR CO.
    45. CAUTION: Damage to the VCT phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.
    CAUTION: Only use hand tools to remove the VCT phaser sprocket assembly or damage may occur to the camshaft or VCT phaser sprocket.
  45. Using the special tool, remove the bolt and the LH VCT phaser sprocket assembly.
    • Discard the VCT phaser sprocket bolt.
      Fig 42: Identifying Special Sprocket Phaser Tool
      G03919955Courtesy of FORD MOTOR CO.
    46. CAUTION: Remove the front thrust camshaft bearing cap straight upward from the bearing towers or the bearing cap may be damaged from sideloading.
    NOTE: The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations.
    Fig 43: Identifying Camshaft Bearing Cap Bolt Loosening/Tightening Sequence
    G03919956Courtesy of FORD MOTOR CO.
  46. Remove the bolts in the sequence shown and remove the RH cylinder head front camshaft bearing cap and then the remaining bearing caps.
  47. Clean and inspect the RH camshaft bearing caps.
    • The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.
      Fig 44: Identifying Camshaft Front Thrust Bearing Cap Oil Metering Groove
      G03919957Courtesy of FORD MOTOR CO.
  48. Remove the RH camshaft.
    49. CAUTION: Remove the front thrust camshaft bearing cap straight upward from the bearing towers or the bearing cap may be damaged from sideloading.
    NOTE: The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations.
    Fig 45: Identifying Camshaft Bearing Cap Bolt Loosening/Tightening Sequence
    G03919956Courtesy of FORD MOTOR CO.
  49. Remove the bolts in the sequence shown and remove the LH cylinder head front camshaft bearing cap and then the remaining bearing caps.
  50. Clean and inspect the LH camshaft bearing caps.
    • The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.
      Fig 46: Identifying Camshaft Front Thrust Bearing Cap Oil Metering Groove
      G03919957Courtesy of FORD MOTOR CO.
  51. Remove the LH camshaft.
    52. CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original locations.
  52. Remove the all of the remaining camshaft roller followers from the cylinder heads.

    53. LH cylinder head 

    CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original locations.
  53. Remove the hydraulic lash adjusters from the LH cylinder head.
  54. Install the special tool onto the LH cylinder head.
    Fig 47: Identifying Special Tool Onto Cylinder Head
    G03920258Courtesy of FORD MOTOR CO.
  55. Remove the 2 nuts and the LH exhaust manifold shield.
    Fig 48: Locating LH Exhaust Manifold Shield Nuts
    G04647246Courtesy of FORD MOTOR CO.
  56. Remove the 8 nuts, the 8 studs and the LH exhaust manifold.
    • Discard the gaskets, the 8 studs and the 8 nuts.
    • Inspect the exhaust manifold. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
      Fig 49: Locating LH Exhaust Manifold Nuts
      G04647247Courtesy of FORD MOTOR CO.

    57. RH cylinder head 

    CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original locations.
  57. Remove the hydraulic lash adjusters from the RH cylinder heads.
  58. Install the special tool onto the RH cylinder head.
    Fig 50: Identifying Special Tool On Cylinder Head
    G03920261Courtesy of FORD MOTOR CO.
  59. Remove the 8 nuts, the 8 studs and the RH exhaust manifold.
    • Discard the gaskets, the 8 studs and the 8 nuts.
    • Inspect the exhaust manifold. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
      Fig 51: Locating RH Exhaust Manifold Nuts And Studs
      G04647249Courtesy of FORD MOTOR CO.
  60. Remove the stud bolt and the coolant tube.
    • Discard the O-ring seals.
      Fig 52: Identifying Coolant Tube Stud Bolt
      G03920263Courtesy of FORD MOTOR CO.

    61. All cylinder heads 

    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: RH shown, LH similar.
  61. Remove the bolts and the cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
      Fig 53: Locating Cylinder Head Bolts
      G03885651Courtesy 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 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.
  62. 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.
    63. 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 within 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 within 0.010 mm (0.0004 in) from end to end.
    NOTE: LH shown, RH similar.
    Fig 54: Identifying Cylinder Head/Cylinder Block Oil Pressure Feed Areas
    G03885653Courtesy of FORD MOTOR CO.
  63. 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 longer than 0.0254 mm (0.001 in).
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