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 463 (Engine - 4.0L SOHC) >> In-Vehicle Repair >> Cylinder Heads >> Removal

Cylinder Heads: Removal

WARNING: This page is about a different car, the 2004 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.

    BOTH CYLINDER HEADS 

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  3. Drain the cooling system. For additional information, refer to ENGINE COOLING .
  4. Remove the intake manifold. For additional information, refer to INTAKE MANIFOLD .
  5. Remove the cooling fan shroud. For additional information, refer to ENGINE COOLING .
  6. Remove the accessory drive belt. For additional information, refer to SPECIFICATIONS & DRIVE BELT ROUTING .
  7. Remove the LH valve cover. For additional information, refer to VALVE COVER LH .
  8. Remove the RH valve cover. For additional information, refer to VALVE COVER - RH .
  9. Disconnect the generator electrical connections.
    Fig 1: Disconnecting Generator Electrical Connections
    G03274510Courtesy of FORD MOTOR CO.
  10. Remove the accessory drive belt tensioner.
    Fig 2: Removing Accessory Drive Belt Tensioner
    G03274511Courtesy of FORD MOTOR CO.
  11. Remove the bolts and the generator mounting bracket and generator as an assembly.
    Fig 3: Removing Generator Mounting Bracket
    G03274512Courtesy of FORD MOTOR CO.
  12. Disconnect the engine wiring harness electrical connector and detach the harness retainers.
    Fig 4: Disconnecting Engine Wiring Harness Electrical Connector
    G03274513Courtesy of FORD MOTOR CO.
  13. Detach the engine wiring harness retainer.
    Fig 5: Detaching Engine Wiring Harness Retainer
    G03274514Courtesy of FORD MOTOR CO.
  14. Disconnect the crankshaft position (CKP) sensor electrical connector.
    Fig 6: Disconnecting CKP Sensor Electrical Connector
    G03274515Courtesy of FORD MOTOR CO.
  15. Disconnect the wiring harness retainers.
    Fig 7: Disconnecting Wiring Harness Retainers
    G03274516Courtesy of FORD MOTOR CO.
  16. Disconnect the coolant temperature indicator sender unit and the engine coolant temperature (ECT) sensor electrical connectors.
    Fig 8: Disconnecting Coolant Temperature Indicator Sender Unit & ECT Sensor Electrical Connectors
    G03274517Courtesy of FORD MOTOR CO.
    17. NOTE: The coolant bypass hose will be removed with the thermostat housing.
    Fig 9: Moving Coolant Bypass Hose Clamp Off Coolant Pump Outlet
    G03274518Courtesy of FORD MOTOR CO.
  17. Move the coolant bypass hose clamp off the coolant pump outlet.
  18. Remove the bolts and the thermostat housing and coolant bypass hose.
    Fig 10: Removing Thermostat Housing And Coolant Bypass Hose
    G03274519Courtesy of FORD MOTOR CO.
  19. Remove the bolt and the wiring harness retainer.
    Fig 11: Removing Wiring Harness Retainer
    G03274520Courtesy of FORD MOTOR CO.
  20. Remove the bolts and position the accessory bracket aside.
    Fig 12: Removing/Positioning Accessory Bracket Aside
    G03274521Courtesy of FORD MOTOR CO.
  21. Disconnect the wiring harness casing from the LH cylinder head.
    Fig 13: Disconnecting Wiring Harness Casing From LH Cylinder Head
    G03274522Courtesy of FORD MOTOR CO.
  22. Remove the bolt and the oil level indicator tube.
    Fig 14: Removing Oil Level Indicator Tube
    G03274523Courtesy of FORD MOTOR CO.
  23. Using the special tool, disconnect the LH spark plug wires from the spark plugs.
    Fig 15: Disconnecting LH Spark Plug Wires From Spark Plugs
    G03274524Courtesy of FORD MOTOR CO.
  24. Disconnect the fuel pulse damper vacuum hose.
    Fig 16: Disconnecting Fuel Pulse Damper Vacuum Hose
    G03274525Courtesy of FORD MOTOR CO.
  25. Remove the fuel injection supply manifold.
    1. Remove the four bolts and disconnect the fuel supply tube from the fuel manifold. Position the fuel supply tube aside.
    2. Remove the four bolts and the supply manifold and the fuel injectors as an assembly.
      Fig 17: Removing Fuel Injection Supply Manifold
      G03274526Courtesy of FORD MOTOR CO.
    26. NOTE: Mark each of the roller followers to ensure it is installed in its original position during reassembly.
    Fig 18: Removing Roller Followers
    G03274527Courtesy of FORD MOTOR CO.
  26. Use the special tool to remove the roller followers.
    27. NOTE: Late build pulley shown, early build pulley similar.
    NOTE: The special tool must be installed on the damper and should contact the engine block. This positions the engine at top dead center (TDC).
    Fig 19: Setting No. 1 Piston To TDC
    G03274528Courtesy of FORD MOTOR CO.
  27. Using the special tool, set the No. 1 piston to TDC.

    28. RH CYLINDER HEAD 

  28. Remove the RH fenderwell splash shield.
    Fig 20: Removing RH Fenderwell Splash Shield
    G03274529Courtesy of FORD MOTOR CO.
  29. Remove the RH camshaft tensioner.
    Fig 21: Removing RH Camshaft Tensioner
    G03274530Courtesy of FORD MOTOR CO.
  30. Remove the RH exhaust manifold. For additional information, refer to EXHAUST MANIFOLD - RH .
  31. Remove the bolt and the bracket.
    Fig 22: Removing Bolt And Bracket
    G03274531Courtesy of FORD MOTOR CO.
    32. CAUTION: The right -hand camshaft sprocket bolt is a left-hand threaded bolt.
    NOTE: If necessary, use camshaft gear torque adapter (303-565) to remove camshaft sprocket bolt.
    Fig 23: Removing RH Camshaft Sprocket Bolt
    G03274532Courtesy of FORD MOTOR CO.
  32. Remove the RH camshaft sprocket bolt.
  33. Remove the chain guide bolt.
    Fig 24: Removing Chain Guide Bolt
    G03274533Courtesy of FORD MOTOR CO.
    34. CAUTION: Remove the camshaft sprocket to prevent breaking the cassette and to gain clearance to remove the cylinder head.
    NOTE: Hold the chain and cassette with a rubber band to aid in removal and prevent the chain from falling into the cylinder block.
    Fig 25: Removing RH Camshaft Sprocket From Cassette
    G03274534Courtesy of FORD MOTOR CO.
  34. Remove the RH camshaft sprocket from the cassette.
  35. Remove the eight 12 mm (0.47 in) bolts and the two 8 mm (0.31 in) bolts in the sequence shown, and remove the RH cylinder head.
    • Discard the head gasket.
    • Discard the cylinder head bolts.
      Fig 26: Cylinder Head Bolts Removal Sequence
      G03274535Courtesy of FORD MOTOR CO.
  36. Clean the gasket mating surfaces.

    37. LH CYLINDER HEAD 

  37. Remove the LH exhaust manifold. For additional information, refer to EXHAUST MANIFOLD LH .
  38. Remove the bolt and the ground strap.
    Fig 27: Removing Ground Strap
    G03274536Courtesy of FORD MOTOR CO.
  39. Remove the engine wiring harness pin-type retainer.
    Fig 28: Removing Engine Wiring Harness Pin-Type Retainer
    G03274537Courtesy of FORD MOTOR CO.
  40. Remove the LH hydraulic chain tensioner.
    Fig 29: Removing LH Hydraulic Chain Tensioner
    G03274538Courtesy of FORD MOTOR CO.
  41. Remove the camshaft sprocket bolt.
    Fig 30: Removing Camshaft Sprocket Bolt
    G03274539Courtesy of FORD MOTOR CO.
  42. Remove the chain guide bolt.
    Fig 31: Removing Chain Guide Bolt
    G03274540Courtesy of FORD MOTOR CO.
    43. CAUTION: Remove the camshaft sprocket to prevent breaking the cassette and to gain clearance to remove the cylinder head.
    NOTE: Hold the chain and cassette with a rubber band to aid in removal and prevent the chain from falling into the cylinder block.
    Fig 32: Removing LH Camshaft Sprocket From Chain Cassette
    G03274541Courtesy of FORD MOTOR CO.
  43. Remove the LH camshaft sprocket from the chain cassette.
  44. Remove the eight 12 mm (0.47 in) bolts and the two 8 mm (0.31 in) bolts in the sequence shown and remove the LH cylinder head.
    • Discard the head gaskets.
    • Discard the cylinder head bolts.
      Fig 33: Cylinder Head Bolts Removal Sequence
      G03274542Courtesy of FORD MOTOR CO.
  45. Clean the gasket mating surfaces.
scientia non olet · About LEMON Manuals