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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 320 (Engine - 4.6L & 5.4L) >> Removal >> Cylinder Heads - 4.6L >> Removal

Cylinder Heads - 4.6L: Removal

WARNING: This page is about a different car, the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E450 Super Duty, and 2003 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

    ALL CYLINDER HEADS 

  1. Remove the engine. For additional information, refer to ENGINE .
  2. Remove the bolts and the flexplate or the flywheel.
    Fig 1: Removing Flywheel Bolts
    G01536623Courtesy of FORD MOTOR CO.
    3. CAUTION: Use care when lowering the engine, to prevent damage to the oil pan.
  3. Lower the engine onto wooden blocks.
  4. Remove the special tool.
    Fig 2: Removing Special Tool
    G01536624Courtesy of FORD MOTOR CO.
  5. Install the special tool.
    Fig 3: Installing Special Tool (1 Of 2)
    G01536625Courtesy of FORD MOTOR CO.
  6. Install the special tool.
    Fig 4: Installing Special Tool (2 Of 2)
    G01536626Courtesy of FORD MOTOR CO.
  7. Mount the engine on a suitable work stand.
  8. Remove the special tool.
    Fig 5: Removing Special Tool (1 Of 2)
    G01536627Courtesy of FORD MOTOR CO.
  9. Remove the special tool.
    Fig 6: Removing Special Tool (2 Of 2)
    G01536628Courtesy of FORD MOTOR CO.
  10. Remove the RH engine mount.
    Fig 7: Removing RH Engine Mount
    G01536629Courtesy of FORD MOTOR CO.
    11. NOTE: LH shown, RH similar.
    Fig 8: Removing Cylinder Block Drain Plugs
    G01536630Courtesy of FORD MOTOR CO.
  11. Remove the cylinder block drain plugs, and drain the coolant in a suitable container.
  12. Disconnect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
    Fig 9: Disconnecting LH Radio Frequency Interference Capacitor
    G01536631Courtesy of FORD MOTOR CO.
  13. Disconnect the camshaft position (CMP) sensor electrical connector.
    Fig 10: Disconnecting Camshaft Position (CMP) Sensor Electrical Connector
    G01536632Courtesy of FORD MOTOR CO.
  14. Disconnect the RH radio frequency interference capacitor electrical connector.
    Fig 11: Disconnecting RH Radio Frequency Interference Capacitor Electrical Connector
    G01536633Courtesy of FORD MOTOR CO.
  15. Disconnect the knock sensor electrical connector.
    Fig 12: Disconnecting Knock Sensor Electrical Connector
    G01536634Courtesy of FORD MOTOR CO.

    16. VEHICLES WITHOUT A/C 

  16. Disconnect the crankshaft position (CKP) sensor electrical connector.
    Fig 13: Disconnecting Crankshaft Position (CKP) Sensor Electrical Connector
    G01536635Courtesy of FORD MOTOR CO.

    17. ALL CYLINDER HEADS 

  17. Disconnect the oil pressure switch electrical connector.
    Fig 14: Disconnecting Oil Pressure Switch Electrical Connector
    G01536636Courtesy of FORD MOTOR CO.
  18. Disconnect all of the harness routing clips and connector retainers. Remove the engine control sensor wiring harness.
    19. NOTE: RH shown, LH similar.
    Fig 15: Removing Two Radio Interference Capacitors
    G01536637Courtesy of FORD MOTOR CO.
  19. Remove the nuts and the two radio interference capacitors.
  20. Remove the crankcase ventilation tube from the LH valve cover.
    Fig 16: Removing Crankcase Ventilation Tube From LH Valve Cover
    G01536638Courtesy of FORD MOTOR CO.
    21. 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.
    Fig 17: Removing LH Valve Cover
    G01536639Courtesy of FORD MOTOR CO.
  21. Remove the LH valve cover.
    • Fully loosen the bolts 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.
    22. 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: Windsor engine shown; Romeo engine similar.
    Fig 18: Removing RH Valve Cover
    G01536640Courtesy of FORD MOTOR CO.
  22. Remove the RH valve cover.
    • Fully loosen the bolts 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.
  23. Remove the bolt and the belt idler pulley.
    Fig 19: Removing Belt Idler Pulley
    G01536641Courtesy of FORD MOTOR CO.
  24. Remove the coolant pump pulley.
    1. Remove the bolts.
    2. Remove the coolant pump pulley.
    Fig 20: Removing Coolant Pump Pulley
    G01536642Courtesy of FORD MOTOR CO.
  25. Remove and discard the crankshaft pulley bolt.

    Use the special tool to remove the crankshaft pulley.

    Fig 21: Removing Crankshaft Pulley
    G01536643Courtesy of FORD MOTOR CO.
  26. Use the special tool to remove the crankshaft front oil seal.
    Fig 22: Removing Crankshaft Front Oil Seal
    G01536644Courtesy of FORD MOTOR CO.
  27. Remove the power steering pump.
    Fig 23: Removing Power Steering Pump
    G01536645Courtesy of FORD MOTOR CO.
  28. Remove the bolts.
    Fig 24: Removing Bolts
    G01536646Courtesy of FORD MOTOR CO.
    29. NOTE: Correct fastener location is essential for assembly procedure. Record fastener location.
    Fig 25: Removing Fasteners
    G01536647Courtesy of FORD MOTOR CO.
  29. Remove the fasteners.
  30. Remove the engine front cover from the cylinder block.
    Fig 26: Removing Engine Front Cover From Cylinder Block
    G01536648Courtesy of FORD MOTOR CO.
  31. Remove the crankshaft sensor ring from the crankshaft.
    Fig 27: Removing Crankshaft Sensor Ring From Crankshaft
    G01536649Courtesy of FORD MOTOR CO.
    32. 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.
  32. Remove the eight spark plugs.
  33. Install the special tool between the valve spring coils to prevent valve stem seal damage.
    Fig 28: Installing Special Tool Between Valve Spring Coils
    G01536650Courtesy of FORD MOTOR CO.
    34. 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 29: Compressing Valve Springs
    G01536651Courtesy of FORD MOTOR CO.
  34. Use the special tool to compress the valve springs, and remove the camshaft roller followers.
  35. Remove the special tool.
    Fig 30: Removing Special Tool
    G01536652Courtesy of FORD MOTOR CO.
  36. Position the crankshaft with the keyway at the 12 o'clock position.
    Fig 31: Positioning Crankshaft
    G01536653Courtesy of FORD MOTOR CO.
  37. 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 32: Removing Timing Chain Tensioner Arms
    G01536654Courtesy of FORD MOTOR CO.
  38. 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 33: Removing LH Timing Chain
    G01536655Courtesy of FORD MOTOR CO.
  39. Remove both timing chain guides.
    • Remove the bolts.
    • Remove both timing chain guides.
    Fig 34: Removing Timing Chain Guides
    G01536656Courtesy of FORD MOTOR CO.

    40. RH CYLINDER HEAD 

  40. Remove the RH exhaust manifold.
    1. Remove the nuts.
    2. Remove the RH exhaust manifold.
    3. Remove the RH exhaust manifold gasket.
    Fig 35: Removing RH Exhaust Manifold
    G01536657Courtesy of FORD MOTOR CO.

    41. LH CYLINDER HEAD 

  41. Remove the LH exhaust manifold.
    1. Remove the nuts.
    2. Remove the LH exhaust manifold.
    3. Remove the LH exhaust manifold gasket.
    Fig 36: Removing LH Exhaust Manifold
    G01536658Courtesy of FORD MOTOR CO.
  42. Remove the bolt and the oil level indicator tube.
    Fig 37: Removing Oil Level Indicator Tube
    G01536659Courtesy of FORD MOTOR CO.

    43. ALL CYLINDER HEADS 

  43. Clean and inspect the exhaust manifolds. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  44. Install the special tools on both ends of the cylinder head.
    Fig 38: Installing Special Tools On Both Ends Of Cylinder Head
    G01536660Courtesy of FORD MOTOR CO.
    45. NOTE: The hydraulic lash adjusters must be reinstalled in their original locations. Record the hydraulic lash adjuster locations.
    Fig 39: Removing Hydraulic Lash Adjusters
    G01536661Courtesy of FORD MOTOR CO.
  45. Remove the hydraulic lash adjusters.

    46. RH CYLINDER HEAD 

    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: 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.
    Fig 40: Identifying Cylinder Head Bolts
    G01536662Courtesy of FORD MOTOR CO.
  46. Remove the bolts and the RH cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.

    47. LH CYLINDER HEAD 

    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: 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.
    Fig 41: Identifying Cylinder Head Bolts
    G01536663Courtesy of FORD MOTOR CO.
  47. Remove the bolts and the RH cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.

    48. ALL CYLINDER HEADS 

    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.
  48. 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.
    49. NOTE: The straightedge used must be flat within 0.0051 mm (0.0002 in) per foot of tool length.
  49. 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).
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