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Cylinder Head - RH

WARNING: This page is about a different car, the 2008 Mercury Sable, 2008 Ford Taurus X, and 2008 Ford Taurus. However, it is still accessible from the selected car via links, so may be relevant.
Material

Item Specification
Motorcraft Metal Surface Prep
ZC-31-A		 -
Silicone Gasket Remover
ZC-30		 -
CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.
  1. Remove the RH camshafts. For additional information, refer to Camshaft .
  2. Disconnect the RH heated oxygen sensor (HO2S) electrical connector.
    3. Fig 1: Locating RH Heated Oxygen Sensor (HO2S) Electrical Connector
    GF0029222Courtesy of FORD MOTOR CO.
  3. Disconnect the RH camshaft position (CMP) sensor electrical connector.
    4. Fig 2: Locating RH Camshaft Position (CMP) Sensor Electrical Connector
    GF0029224Courtesy of FORD MOTOR CO.
  4. Remove the bolt and the RH CMP sensor.
    5. Fig 3: Locating RH CMP Sensor & Bolt
    GF0029239Courtesy of FORD MOTOR CO.
  5. Remove the bolt and the power steering pressure (PSP) tube bracket from the RH cylinder head.
    6. Fig 4: Identifying Bolt
    GF0045680Courtesy of FORD MOTOR CO.
  6. Remove the bolt and the ground wire.
    7. Fig 5: Identifying Bolt
    GF0045681Courtesy of FORD MOTOR CO.
  7. Disconnect the 6 fuel injector electrical connectors (3 shown).
    8. Fig 6: Locating Fuel Injector Electrical Connectors
    GF0029226Courtesy of FORD MOTOR CO.
  8. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
    9. Fig 7: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector
    GF0029227Courtesy of FORD MOTOR CO.
  9. Disconnect the LH catalyst monitor sensor electrical connector.
    10. Fig 8: Identifying LH Catalyst Monitor Sensor Electrical Connector
    GF0041326Courtesy of FORD MOTOR CO.
  10. Remove the 2 LH catalytic converter bracket bolts.
    11. Fig 9: Locating LH Catalytic Converter Bracket Bolts
    GF0029229Courtesy of FORD MOTOR CO.
  11. Remove the 4 nuts (3 shown) and the LH catalytic converter.
    • Discard the nuts and the gasket.
    12. Fig 10: Locating LH Catalytic Converter Nuts
    GF0029230Courtesy of FORD MOTOR CO.
  12. Remove the LH cylinder block drain plug.
    • Allow coolant to drain from the cylinder block.
    13. Fig 11: Locating LH Cylinder Block Drain Plug
    GF0029231Courtesy of FORD MOTOR CO.
  13. Remove the 4 nuts and the RH catalytic converter.
    • Discard the nuts and gasket.
    14. Fig 12: Identifying Nuts
    GF0045670Courtesy of FORD MOTOR CO.
  14. If equipped, remove the heat shield and disconnect the block heater electrical connector.
    • Remove the block heater wiring harness from the engine.
    15. Fig 13: Identifying Block Heater Wiring Harness
    GF0029221Courtesy of FORD MOTOR CO.
  15. Remove the RH cylinder block drain plug or, if equipped, the block heater.
    • Allow coolant to drain from the cylinder block.
    16. Fig 14: Locating RH Cylinder Block Drain Plug
    GF0029232Courtesy of FORD MOTOR CO.
  16. Remove the 3 bolts and the RH exhaust manifold heat shield.
    17. Fig 15: Locating RH Exhaust Manifold Heat Shield & Nuts
    GF0029233Courtesy of FORD MOTOR CO.
  17. Remove the 6 nuts and the RH exhaust manifold.
    • Discard the nuts and exhaust manifold gaskets.
    18. Fig 16: Locating RH Exhaust Manifold & Nuts
    GF0029234Courtesy of FORD MOTOR CO.
  18. Clean and inspect the RH exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
  19. Remove and discard the 6 RH exhaust manifold studs.
    20. Fig 17: Locating RH Exhaust Manifold Studs
    GF0029119Courtesy of FORD MOTOR CO.
  20. Remove the 2 bolts and the RH primary timing chain guide.
    21. Fig 18: Locating RH Primary Timing Chain Guide Lower Bolt
    GF0029210Courtesy of FORD MOTOR CO.
  21. Remove the bolts and the RH secondary timing chain tensioner.
    22. Fig 19: Locating RH Secondary Timing Chain Tensioner & Bolts
    GF0029235Courtesy of FORD MOTOR CO.
  22. Remove the 2 bolts and the engine lifting eye.
    23. Fig 20: Locating Engine Lifting Eye & Bolts
    GF0029236Courtesy of FORD MOTOR CO.
    NOTE: Index-mark the location of the bracket on the cylinder head for installation.
  23. If equipped, remove the bolt and the upper intake manifold long support bracket.
    24. Fig 21: Locating Upper Intake Manifold Bracket & Bolt
    GF0029237Courtesy of FORD MOTOR CO.
    NOTE: Index-mark the location of the bracket on the cylinder head for installation.
  24. Remove the bolt and the upper intake manifold short support bracket.
    25. Fig 22: Identifying Bolt And Support Bracket
    GF0045682Courtesy of FORD MOTOR CO.
  25. Remove the coolant by-pass hose from the thermostat housing.
    26. Fig 23: Identifying Coolant By-Pass Hose
    GF0045683Courtesy of FORD MOTOR CO.
  26. Remove the 4 bolts and the fuel rail and injectors as an assembly.
    27. Fig 24: Locating Fuel Rail And Injectors & Bolts
    GF0029240Courtesy of FORD MOTOR CO.
  27. Remove the 3 thermostat housing-to-lower intake manifold bolts.
    • Remove the thermostat housing and discard the gasket and O-ring seal.
    28. Fig 25: Locating Thermostat Housing-To-Lower Intake Manifold Bolts
    GF0031413Courtesy of FORD MOTOR CO.
  28. Remove the 10 bolts and the lower intake manifold.
    • Discard the gaskets.
    29. Fig 26: Locating Lower Intake Manifold Bolts
    GF0029242Courtesy of FORD MOTOR CO.
  29. Disconnect and remove the CHT sensor jumper harness.
    30. Fig 27: Identifying CHT Sensor Jumper Harness
    GF0029243Courtesy of FORD MOTOR CO.
    NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations.
  30. Remove the valve tappets from the cylinder head.
    31. Fig 28: Identifying Valve Tappets From Cylinder Head
    GF0029217Courtesy of FORD MOTOR CO.
  31. Inspect the valve tappets. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
  32. Remove and discard the M6 bolt.
    33. Fig 29: Identifying M6 Bolt
    GF0029244Courtesy of FORD MOTOR CO.
    CAUTION: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.
    CAUTION: Aluminum surfaces are soft and may be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
    NOTE: The cylinder head bolts must be discarded and new bolts must be installed. They are tighten-to-yield design and cannot be reused.
  33. Remove and discard the 8 bolts from the cylinder head.
    • Remove the cylinder head.
    • Discard the cylinder head gasket.
    34. Fig 30: Identifying Cylinder Head Bolts
    GF0029245Courtesy 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.
    NOTE: 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.
  34. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder heads and the cylinder block in the following sequence.
    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.
  35. Support the cylinder head on a bench with the head gasket side up.
    36. NOTE: The straightedge used must be flat within 0.0051 mm (0.0002 in) per foot of tool length.
  36. Inspect all areas of the deck face with a straightedge and feeler gauge. 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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