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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 551 (Engine - 4.0L) >> In-Vehicle Repair >> Cylinder Head >> Removal

Cylinder Head: Removal

WARNING: This page is about a different car, the 2004 Mercury Mountaineer and 2004 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 & 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 AND HYDRAULIC LASH ADJUSTER .
  4. Remove the accessory drive belt tensioner. For additional information, refer to ACCESSORY DRIVE BELT, TENSIONER AND PULLEY .

    5. RH side 

  5. Disconnect the generator electrical connections and disconnect the pushpin.
    Fig 1: Disconnecting Generator Electrical Connections
    G03180478Courtesy of FORD MOTOR CO.
  6. Remove the generator mounting bracket assembly.
    Fig 2: Removing Generator Mounting Bracket Assembly
    G03180479Courtesy of FORD MOTOR CO.
  7. Remove the heater hose from the thermostat housing.
    Fig 3: Removing Heater Hose From Thermostat Housing
    G03180480Courtesy of FORD MOTOR CO.
  8. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
    Fig 4: Disconnecting Engine Coolant Temperature (ECT) Sensor Electrical Connector
    G03180481Courtesy of FORD MOTOR CO.
  9. Disconnect the upper radiator hose.
    Fig 5: Disconnecting Upper Radiator Hose
    G03180482Courtesy of FORD MOTOR CO.
  10. Position the coolant bypass hose clamp aside.
    Fig 6: Positioning Coolant Bypass Hose Clamp
    G03180483Courtesy of FORD MOTOR CO.
  11. Remove the bolts and the thermostat housing.
    Fig 7: Removing Bolts And Thermostat Housing
    G03180484Courtesy 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 And Position Engine Wiring Harness
    G03180485Courtesy of FORD MOTOR CO.
  13. Remove the engine ground strap.
    Fig 9: Removing Engine Ground Strap
    G03180486Courtesy 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
    G03180487Courtesy of FORD MOTOR CO.
  15. Remove the bolts.
    Fig 11: Removing Bolts
    G03180488Courtesy of FORD MOTOR CO.
  16. Remove the bolts and position the accessory bracket aside.
    Fig 12: Removing Bolts And Position Accessory Bracket
    G03180489Courtesy of FORD MOTOR CO.
  17. Remove the bolts and the coil bracket.
    Fig 13: Removing Bolts And Coil Bracket
    G03180490Courtesy of FORD MOTOR CO.
  18. Remove the oil level indicator tube.
    Fig 14: Removing Oil Level Indicator Tube
    G03180491Courtesy 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 All Of Spark Plug Wires From Spark Plugs
    G03180492Courtesy 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
    G03180493Courtesy of FORD MOTOR CO.
    21. NOTE: LH side shown, RH side similar.
    Fig 17: Removing Four Catalytic Converter-To-Manifold Nuts
    G03180494Courtesy of FORD MOTOR CO.
  21. Remove the four 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
    G03180495Courtesy of FORD MOTOR CO.

    23. RH side 

  23. Remove the RH side hydraulic chain tensioner.
    Fig 19: Removing RH Side Hydraulic Chain Tensioner
    G03180496Courtesy of FORD MOTOR CO.
  24. Install the special tools.
    Fig 20: Installing Special Tools
    G03180497Courtesy 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
    G03180498Courtesy of FORD MOTOR CO.
  26. Remove the RH side cassette bolt.
    Fig 22: Removing RH Side Cassette Bolt
    G03180499Courtesy 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
    G03180500Courtesy 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: Removing LH Side Hydraulic Chain Tensioner
    G03180501Courtesy of FORD MOTOR CO.
  29. Install the special tools. Tighten the top clamp bolts to 10 Nm (89 lb-in).
    Fig 25: Installing Special Tools
    G03180502Courtesy of FORD MOTOR CO.
  30. Remove the LH side camshaft sprocket bolt.
    Fig 26: Removing LH Side Camshaft Sprocket Bolt
    G03180503Courtesy of FORD MOTOR CO.
  31. Remove the LH side cassette bolt.
    Fig 27: Removing LH Side Cassette Bolt
    G03180504Courtesy 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
    G03180505Courtesy 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.
    Fig 29: Removing Cylinder Heads
    G03180506Courtesy of FORD MOTOR CO.
  33. Remove the cylinder heads.
    • Remove the cylinder head bolts in the sequence shown. Discard all bolts.
    • Remove and discard the head gasket.
    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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