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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 798 (Engine - 6.8L- E350 & E450) >> Removal >> Cylinder Heads >> Removal & Installation

Removal & Installation

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    Both cylinder heads 

  1. Remove the engine. For additional information, refer to Engine .
  2. Remove the bolts and the flexplate.
    Fig 1: Removing Bolts
    G03886544Courtesy of FORD MOTOR CO.
    3. CAUTION: To prevent damage to the oil pan, use care when lowering the engine.
  3. Lower the engine onto wooden blocks.
  4. Remove the special tool.
    Fig 2: Identifying Special Tool
    G03885604Courtesy of FORD MOTOR CO.
  5. Install the special tool.
    Fig 3: Identifying Special Tool
    G03905704Courtesy of FORD MOTOR CO.
  6. Install the special tool.
    Fig 4: Identifying Special Tool
    G03905705Courtesy of FORD MOTOR CO.
  7. Mount the engine on a suitable work stand.
  8. Remove the special tool.
    Fig 5: Identifying Special Tool
    G03905704Courtesy of FORD MOTOR CO.
  9. Remove the special tool.
    Fig 6: Identifying Special Tool
    G03905705Courtesy of FORD MOTOR CO.
  10. Remove the RH engine mount.
    Fig 7: Removing/Installing RH Engine Mount
    G03885618Courtesy of FORD MOTOR CO.
    11. NOTE: LH shown, RH similar.
    Fig 8: Locating Cylinder Block Drain Plugs
    G03885619Courtesy of FORD MOTOR CO.
  11. Remove the cylinder block drain plugs and drain the coolant into a suitable container.
  12. Disconnect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
    Fig 9: Locating Radio Frequency Interference Capacitor And Cylinder Head Temperature Sensor Electrical Connectors
    G03962635Courtesy of FORD MOTOR CO.
  13. Disconnect the camshaft position (CMP) electrical connector.
    Fig 10: Identifying Camshaft Position (CMP) Sensor Electrical Connector
    G03885221Courtesy of FORD MOTOR CO.
  14. Disconnect the RH radio frequency interference capacitor electrical connector.
    Fig 11: Locating Radio Frequency Interference Capacitor Electrical Connector
    G03885622Courtesy of FORD MOTOR CO.
  15. Disconnect the knock sensor (KS) electrical connector, if equipped.
    Fig 12: Locating KS Electrical Connector
    G03886734Courtesy of FORD MOTOR CO.
  16. Disconnect the crankshaft position (CKP) sensor electrical connector.
    Fig 13: Locating CKP Sensor Electrical Connector
    G04612789Courtesy of FORD MOTOR CO.
  17. Disconnect the oil pressure switch electrical connector.
    Fig 14: Locating Oil Pressure Switch Electrical Connector
    G03886309Courtesy 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: Identifying Radio Frequency Interference Capacitors
    G03906363Courtesy of FORD MOTOR CO.
  19. Remove the nuts and the two radio interference capacitors.
  20. Remove the positive crankcase ventilation (PCV) valve tube from the LH valve cover and position aside.
    Fig 16: Removing Positive Crankcase Ventilation Valve Tube
    G03886367Courtesy of FORD MOTOR CO.
  21. Remove the nut attaching the oil level indicator tube to the front of the engine.
    Fig 17: Removing Nut
    G03886680Courtesy of FORD MOTOR CO.
  22. Remove the bolt attaching the oil level indicator tube to the rear of the engine.
    Fig 18: Removing Bolt
    G03886681Courtesy of FORD MOTOR CO.
  23. Position the oil level indicator tube aside.
    Fig 19: Positioning Oil Level Indicator Tube
    G03886682Courtesy 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.
    NOTE: The bolts are part of the valve cover and should not be removed.
  24. 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.
      Fig 20: Removing LH Valve Cover
      G03886378Courtesy of FORD MOTOR CO.
    25. 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.
  25. 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.
      Fig 21: Identifying RH Valve Cover Bolts
      G03886406Courtesy of FORD MOTOR CO.
  26. Remove the bolt and the idler pulley.
    Fig 22: Identifying Bolt And Belt Idler Pulley
    G03885293Courtesy of FORD MOTOR CO.
  27. Remove the water pump pulley.
    1. Remove the bolts.
    2. Remove the water pump pulley.
      Fig 23: Identifying Coolant Pump Pulley And Bolts
      G03885632Courtesy of FORD MOTOR CO.
  28. Remove and discard the crankshaft pulley bolt. Use the special tool to remove the crankshaft pulley.
    Fig 24: Removing Crankshaft Pulley Bolt Using Special Tool
    G03885277Courtesy of FORD MOTOR CO.
  29. Using the special tool, remove the crankshaft front seal.
    Fig 25: Identifying Crankshaft Front Seal And Special Tool
    G03885682Courtesy of FORD MOTOR CO.
  30. Remove the power steering pump.
    Fig 26: Locating Power Steering Pump Bolts
    G03885288Courtesy of FORD MOTOR CO.
  31. Remove the four oil pan bolts.
    Fig 27: Locating Front Oil Pan Bolts
    G03885636Courtesy of FORD MOTOR CO.
    32. NOTE: Correct fastener location is essential for assembly procedure. Record fastener location.
    Fig 28: Identifying Front Cover Fasteners
    G03885685Courtesy of FORD MOTOR CO.
  32. Remove the fasteners.
  33. Remove the engine front cover from the cylinder block.
    Fig 29: Removing Engine Front Cover From Cylinder Block
    G03885740Courtesy of FORD MOTOR CO.
  34. Remove the crankshaft sensor ring from the crankshaft.
    Fig 30: View Of Crankshaft Sensor Ring At Crankshaft
    G04583449Courtesy of FORD MOTOR CO.
    35. CAUTION: The caps must be marked for installation in their original location or damage to the engine may occur.
    Fig 31: Removing Bolts
    G03886458Courtesy of FORD MOTOR CO.
  35. Remove the six bolts and remove the balance shaft bearing caps.
  36. Remove the balance shaft.
    Fig 32: Removing Balance Shaft
    G03886459Courtesy of FORD MOTOR CO.
    37. 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.
  37. Remove the 10 spark plugs.
  38. Install the special tool between the valve spring coils to prevent valve stem seal damage.
    Fig 33: Installing Special Tool Between Valve Spring Coils
    G03881599Courtesy of FORD MOTOR CO.
    39. 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 34: Compressing Valve Springs
    G03905494Courtesy of FORD MOTOR CO.
  39. Use the special tool to compress the valve springs and remove the camshaft roller followers.
  40. Position the crankshaft with the keyway at the 12 o'clock position.
    Fig 35: Positioning Crankshaft With Keyway At 12 O'Clock Position
    G04583456Courtesy of FORD MOTOR CO.
    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.
  41. 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 36: Identifying Timing Chain Tensioning System Components
      G03885312Courtesy of FORD MOTOR CO.
  42. Remove the RH and LH timing chains and the crankshaft sprocket(s).
    • 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 from the crankshaft sprocket.
      Fig 37: Removing Timing Chain
      G03885313Courtesy of FORD MOTOR CO.
  43. Remove both timing chain guides.
    • Remove the bolts.
    • Remove the timing chain guides.
      Fig 38: Removing Timing Chain Guides
      G03885314Courtesy of FORD MOTOR CO.

    44. RH cylinder head 

  44. Remove the RH exhaust manifold.
    • Remove the nuts.
    • Remove the RH exhaust manifold.
    • Remove the RH exhaust manifold gasket.
      Fig 39: Removing RH Exhaust Manifold
      G03886702Courtesy of FORD MOTOR CO.

    45. LH cylinder head 

  45. Remove the LH exhaust manifold.
    • Remove the nuts.
    • Remove the LH exhaust manifold.
    • Remove the LH exhaust manifold gasket.
      Fig 40: Removing LH Exhaust Manifold
      G03886703Courtesy of FORD MOTOR CO.

    46. Both cylinder heads 

  46. Clean and inspect the exhaust manifolds. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  47. Install the special tools on both ends of the cylinder head.
    Fig 41: Installing/Removing Special Tools On Both Ends Of Cylinder Head
    G03885649Courtesy of FORD MOTOR CO.
    48. NOTE: The hydraulic lash adjusters must be reinstalled in their original locations. Record the hydraulic lash adjuster locations.
    Fig 42: Identifying Hydraulic Lash Adjusters
    G03885650Courtesy of FORD MOTOR CO.
  48. Remove the hydraulic lash adjusters.

    49. 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 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 which 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.
  49. Remove the bolts and the RH cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
      Fig 43: Removing Bolts RH Cylinder Head
      G03886706Courtesy of FORD MOTOR CO.

    50. 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 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 which 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.
  50. Remove the bolts and the RH cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
      Fig 44: Removing Bolts RH Cylinder Head
      G03886706Courtesy of FORD MOTOR CO.

    51. Both 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 which 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 surfaces.
  51. 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 surface is normal.
    52. 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 machine edge must be flat with 0.010 mm (0.0004 in) from end to end.
    NOTE: LH is shown, RH is similar.
    Fig 45: Identifying Oil Pressure Feed Area Of Deck Face Surface
    G03885653Courtesy of FORD MOTOR CO.
  52. 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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