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Cylinder Heads

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.
Fig 1: Identifying Special Service Tool
G03181196Courtesy of FORD MOTOR CO.
MATERIAL SPECIFICATION CHART

Item Specification
Motorcraft Silicone Gasket Remover ZC-30 -
Motorcraft Metal Surface Prep ZC-31 -
  1. Remove the engine. For additional information, refer to ENGINE .
  2. Remove the bolts and the flexplate.
    Fig 2: Removing Flexplate
    G03181197Courtesy of FORD MOTOR CO.
  3. Remove the spacer plate.
    Fig 3: Removing Spacer Plate
    G03181198Courtesy of FORD MOTOR CO.
  4. Install the engine on a suitable engine stand.
  5. Rotate the belt tensioner and remove the accessory drive belt.
    Fig 4: Removing Accessory Drive Belt
    G03181199Courtesy of FORD MOTOR CO.
  6. Disconnect the oil pressure sensor electrical connector.
  7. Remove the nuts and position the wiring harness bracket aside.
    Fig 5: Removing Wiring Harness Bracket Aside
    G03181200Courtesy of FORD MOTOR CO.
  8. Remove the power steering hose support bracket.
    Fig 6: Removing Power Steering Hose Support Bracket
    G03181201Courtesy of FORD MOTOR CO.
  9. Disconnect the return and pressure hoses from the power steering pump.
    Fig 7: Disconnecting Pressure Hoses From Power Steering Pump
    G03181202Courtesy of FORD MOTOR CO.
  10. Remove the bolts and the power steering pump.
    Fig 8: Removing Power Steering Pump
    G03181203Courtesy of FORD MOTOR CO.
  11. Remove the nut and position the radio capacitor and ground cable aside.
    Fig 9: Removing Radio Capacitor And Ground Cable
    G03181204Courtesy of FORD MOTOR CO.
  12. Remove the power steering reservoir and bracket from the stud.
    Fig 10: Removing Power Steering Reservoir And Bracket
    G03181205Courtesy of FORD MOTOR CO.
  13. Disconnect the A/C compressor and crankshaft position (CKP) sensor electrical connectors.
    Fig 11: Disconnecting A/C Compressor And Crankshaft Position (CKP) Sensor Electrical Connectors
    G03181206Courtesy of FORD MOTOR CO.
  14. Disconnect the wiring harness retainers.
    Fig 12: Disconnecting Wiring Harness Retainers
    G03181207Courtesy of FORD MOTOR CO.
  15. Detach the wiring harness retainer from the A/C tube.
    Fig 13: Disconnecting Wiring Harness Retainer From A/C Tube
    G03181208Courtesy of FORD MOTOR CO.
  16. Remove the bolt and position the wiring harness aside.
    Fig 14: Removing Wiring Harness
    G03181209Courtesy of FORD MOTOR CO.
  17. Remove the crankcase air inlet tube.
    Fig 15: Removing Crankcase Air Inlet Tube
    G03181210Courtesy of FORD MOTOR CO.
  18. Remove the nut and the upper radiator hose bracket and position the radio interference capacitor aside.
    Fig 16: Removing Upper Radiator Hose Bracket
    G03181211Courtesy of FORD MOTOR CO.
  19. Remove the bolts and the idler pulleys.
    Fig 17: Removing Idler Pulleys
    G03181212Courtesy of FORD MOTOR CO.
  20. Disconnect the generator electrical connectors and pin-type retainer.
    Fig 18: Disconnecting Generator Electrical Connectors And Pin-Type Retainer
    G03181213Courtesy of FORD MOTOR CO.
  21. Remove the bolts and the bracket.
    Fig 19: Removing Bolts And Bracket
    G03181214Courtesy of FORD MOTOR CO.
  22. Remove the bolts and the generator.
    Fig 20: Removing Bolts And Generator
    G03181215Courtesy of FORD MOTOR CO.
  23. Disconnect the electrical connector and remove the bolt and the camshaft position (CMP) sensor.
    Fig 21: Disconnecting CMP Sensor Electrical Connector
    G03181216Courtesy of FORD MOTOR CO.
  24. Remove the bolts and the coolant pump pulley.
  25. Remove the exhaust gas recirculation (EGR) system module-to-manifold tube.
    Fig 22: Removing Exhaust Gas Recirculation (EGR) System Module-To-Manifold Tube
    G03181217Courtesy of FORD MOTOR CO.
  26. Remove the RH exhaust manifold heat shield.
    Fig 23: Removing RH Exhaust Manifold Heat Shield
    G03181218Courtesy of FORD MOTOR CO.
  27. Remove the RH exhaust manifold.
    1. Remove the 8 nuts.
    2. Remove the RH exhaust manifold.
    3. Remove and discard the RH exhaust manifold gasket.
    Fig 24: Removing RH Exhaust Manifold Gasket
    G03181219Courtesy of FORD MOTOR CO.
  28. Remove the LH exhaust manifold heat shield.
    Fig 25: Removing LH Exhaust Manifold Heat Shield
    G03181220Courtesy of FORD MOTOR CO.
  29. Remove the LH exhaust manifold.
    1. Remove the 8 nuts.
    2. Remove the LH exhaust manifold.
    3. Remove and discard the LH exhaust manifold gasket.
    Fig 26: Removing LH Exhaust Manifold Gasket
    G03181221Courtesy of FORD MOTOR CO.
  30. Remove the bolt and the oil level indicator tube.
    Fig 27: Removing Oil Level Indicator Tube
    G03181222Courtesy of FORD MOTOR CO.
  31. Clean and inspect the exhaust manifolds. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  32. Remove the bolt and the brake booster vacuum hose.
    Fig 28: Removing Brake Booster Vacuum Hose
    G03181223Courtesy of FORD MOTOR CO.
  33. Disconnect the throttle position (TP) sensor and the electronic throttle body electrical connectors.
    Fig 29: Disconnecting Throttle Position (TP) Sensor And Electronic Throttle Body Electrical Connectors
    G03181224Courtesy of FORD MOTOR CO.
  34. Remove the positive crankcase ventilation (PCV) tube and disconnect the vacuum tube from the throttle body adapter.
    Fig 30: Removing Positive Crankcase Ventilation (PCV) Tube
    G03181225Courtesy of FORD MOTOR CO.
  35. Disconnect the EGR system module and fuel pressure sensor vacuum fittings.
    • Remove the vacuum harness from the engine.
    Fig 31: Removing Vacuum Harness From Engine
    G03181226Courtesy of FORD MOTOR CO.
  36. Disconnect the EGR system module and fuel pressure sensor electrical connectors.
    Fig 32: Disconnecting EGR System Module And Fuel Pressure Sensor Electrical Connectors
    G03181227Courtesy of FORD MOTOR CO.
  37. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
    Fig 33: Disconnecting Cylinder Head Temperature (CHT) Sensor Electrical Connector
    G03181228Courtesy of FORD MOTOR CO.
  38. Disconnect the knock sensor (KS) electrical connector and the wiring harness pin-type retainer.
    Fig 34: Disconnecting Knock Sensor (KS) Electrical Connector And Wiring Harness Pin-Type Retainer
    G03181229Courtesy of FORD MOTOR CO.
  39. Disconnect the coolant hoses.
    Fig 35: Disconnecting Coolant Hoses (1 Of 2)
    G03181230Courtesy of FORD MOTOR CO.
  40. Disconnect the coolant hose.
    Fig 36: Disconnecting Coolant Hoses (2 Of 2)
    G03181231Courtesy of FORD MOTOR CO.
  41. Remove the bolts and the electronic throttle body and adapter.
    Fig 37: Removing Electronic Throttle Body
    G03181232Courtesy of FORD MOTOR CO.
  42. Disconnect the RH fuel injector, coil and ground electrical connectors and the wiring harness retainers.
    Fig 38: Disconnecting RH Fuel Injector, Coil And Ground Electrical Connectors And Wiring Harness Retainers
    G03181233Courtesy of FORD MOTOR CO.
  43. Disconnect the LH fuel injector and coil pack electrical connectors and the fuel charging wiring harness retainers.
    Fig 39: Disconnecting LH Fuel Injector, Coil And Ground Electrical Connectors And Wiring Harness Retainers
    G03181234Courtesy of FORD MOTOR CO.
  44. Disconnect the wiring harness retainers.
    Fig 40: Disconnecting Wiring Harness Retainers
    G03181235Courtesy of FORD MOTOR CO.
  45. Disconnect the ground wire.
    Fig 41: Disconnecting Ground Wire
    G03181236Courtesy of FORD MOTOR CO.
  46. Disconnect all remaining wiring harness retainers and remove the fuel charging wiring harness.
    47. NOTE: LH is shown, RH is similar.
    Fig 42: Removing Ignition Coils
    G03181237Courtesy of FORD MOTOR CO.
  47. Remove the bolts and all 8 ignition coils.
  48. Remove the bolts and the thermostat housing.
    Fig 43: Removing Thermostat Housing
    G03181238Courtesy of FORD MOTOR CO.
  49. Remove the 9 bolts and the intake manifold.
    Fig 44: Removing Intake Manifold
    G03181239Courtesy of FORD MOTOR CO.
  50. Remove the intake manifold gaskets.
    Fig 45: Removing Intake Manifold Gaskets
    G03181240Courtesy 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.
  51. Clean the sealing surfaces.
  52. Remove the bolts and the LH engine mount.
    Fig 46: Removing LH Engine Mount
    G03181241Courtesy of FORD MOTOR CO.
  53. Remove the bolts and the RH engine mount.
    Fig 47: Removing RH Engine Mount
    G03181242Courtesy of FORD MOTOR CO.
  54. Remove the RH cylinder block drain plug.
    • Reinstall the drain plug after draining the coolant.
    Fig 48: Removing RH Cylinder Block Drain Plug
    G03181243Courtesy of FORD MOTOR CO.
  55. Remove the LH cylinder block drain plug.
    • Reinstall the drain plug after draining the coolant.
    Fig 49: Removing LH Cylinder Block Drain Plug
    G03181244Courtesy of FORD MOTOR CO.
    56. 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.
    NOTE: There are several kinds of bolts used in fastening the valve cover. The bolts must be installed in their original locations.
    Fig 50: Identifying LH Valve Cover
    G03181245Courtesy of FORD MOTOR CO.
  56. Remove the LH valve cover.
    • Clean and inspect the mating surfaces and if necessary, install new gaskets.
    57. 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.
    NOTE: There are several kinds of bolts used in fastening the valve cover. The bolts must be installed in their original locations.
    Fig 51: Identifying RH Valve Cover
    G03181246Courtesy of FORD MOTOR CO.
  57. Remove the RH valve cover.
    • Clean and inspect the mating surfaces and if necessary, install new gaskets.
    58. NOTE: Use compressed air to remove any foreign material from the spark plug wells before removing the spark plugs.
  58. Remove the spark plugs.
  59. Remove the crankshaft pulley bolt. Using the special tool, remove the crankshaft pulley.
    Fig 52: Removing Crankshaft Pulley Bolt
    G03181247Courtesy of FORD MOTOR CO.
  60. Using the special tool, remove the crankshaft front oil seal.
    Fig 53: Removing Crankshaft Front Oil Seal
    G03181248Courtesy of FORD MOTOR CO.
  61. Remove the 4 oil pan bolts.
    Fig 54: Removing Oil Pan Bolts
    G03181249Courtesy 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 which make leak paths.
    Fig 55: Removing Engine Front Cover
    G03181250Courtesy of FORD MOTOR CO.
  62. Remove the studs, bolts and the engine front cover.
  63. Remove the front cover gaskets, clean and inspect the front cover sealing surfaces.
  64. Remove the crankshaft sensor ring from the crankshaft.
    Fig 56: Removing Crankshaft Sensor Ring From Crankshaft
    G03181251Courtesy of FORD MOTOR CO.
  65. Install the special tool between the valve spring coils to prevent valve stem seal damage.
    Fig 57: Installing Special Tool Between Valve Spring Coils
    G03181252Courtesy of FORD MOTOR CO.
    66. NOTE: Mark the followers for installation in their original locations.
    NOTE: Position the cam lobe away from the camshaft roller follower prior compressing the valve spring.
    Fig 58: Removing Camshaft Roller Followers
    G03181253Courtesy of FORD MOTOR CO.
  66. Using the special tool to compress the valve spring, remove the camshaft roller followers.
    67. 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 59: Removing Timing Chain Tensioner Arms
    G03181254Courtesy of FORD MOTOR CO.
  67. 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.
  68. Remove the LH and the RH timing chains and the crankshaft sprocket.
    Fig 60: Removing LH And RH Timing Chains And Crankshaft Sprocket
    G03181255Courtesy of FORD MOTOR CO.
    69. NOTE: LH shown, RH similar.
    Fig 61: Removing Timing Chain Guides
    G03181256Courtesy of FORD MOTOR CO.
  69. Remove the bolts and both timing chain guides.
  70. Install the lifting handles on both ends of the cylinder head.
    Fig 62: Installing Lifting Handles
    G03181257Courtesy of FORD MOTOR CO.
    71. NOTE: The hydraulic lash adjusters must be installed in their original locations. Record hydraulic lash adjuster locations.
    Fig 63: Removing Hydraulic Lash Adjuster
    G03181258Courtesy of FORD MOTOR CO.
  71. Remove the hydraulic lash adjuster.
  72. Remove the nut and the coolant tube.
    Fig 64: Removing Nut And Coolant Tube
    G03181259Courtesy of FORD MOTOR CO.
    73. 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 torque-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 65: Removing RH Cylinder Head
    G03181260Courtesy of FORD MOTOR CO.
  73. Remove the bolts and the RH cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
    74. 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 torque-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 66: Removing LH Cylinder Head
    G03181261Courtesy of FORD MOTOR CO.
    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.
  74. Remove the bolts and the LH cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
  75. Clean the cylinder head-to-cylinder block mating surfaces of both 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.
    76. 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 with 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 with 0.010 mm (0.0004 in) from end to end.
    NOTE: LH is shown, RH is similar.
    Fig 67: Identifying Oil Pressure Feed Area
    G03181262Courtesy of FORD MOTOR CO.
  76. 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).
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