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Home >> Ford >> 2009 >> Flex Limited, FWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1777 (Engine Mechanical - 2.5L (Except Hybrid)) >> In-Vehicle Repair >> Cylinder Head >> Removal

Cylinder Head: Removal

WARNING: This page is about a different car, the 2010 Mercury Mariner and 2010 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.
NOTE: 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. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING -- ESCAPE, ESCAPE HYBRID, MARINER & MARINER HYBRID .
  2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  3. Drain the engine cooling system. For additional information, refer to ENGINE COOLING .
  4. Remove the Variable Camshaft Timing (VCT) oil control solenoid. For additional information, refer to ELECTRONIC ENGINE CONTROLS - 2.5L .
  5. Remove the timing drive components. For additional information, refer to TIMING DRIVE COMPONENTS .
  6. Remove the Camshaft Alignment Plate.
    Fig 1: Identifying Camshaft Alignment Plate
    G06094847Courtesy of FORD MOTOR CO.
  7. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.
    Fig 2: Identifying Camshaft Lobe Position
    G06094924Courtesy of FORD MOTOR CO.
    8. NOTE: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.
    NOTE: Mark the location and orientation of each camshaft bearing cap.
  8. Remove the camshafts from the engine.
    • Loosen the camshaft bearing cap bolts, in sequence, one turn at a time until all tension is released from the camshaft bearing caps.
    • Remove the bolts and the camshaft bearing caps.
    • Remove the camshafts.
      Fig 3: Identifying Camshaft Bearing Cap Bolts Loosening Sequence
      G06094925Courtesy of FORD MOTOR CO.
    9. NOTE: If the camshafts and valve tappets are to be reused, mark the location of the valve tappets to make sure they are assembled in their original positions.
  9. Remove the valve tappets.
    10. NOTE: The number on the valve tappets only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm.
  10. Inspect the valve tappets. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
  11. Remove the intake manifold. For additional information, refer to INTAKE MANIFOLD .
  12. Remove the generator. For additional information, refer to CHARGING SYSTEM .
  13. Remove the exhaust manifold. For additional information, refer to EXHAUST MANIFOLD .
  14. Disconnect the EGR valve electrical connector.
  15. Disconnect the EGR coolant hose from the EGR valve.
  16. Disconnect the upper radiator hose, coolant bypass hose, heater hose and coolant vent hose from the engine coolant outlet.
  17. Remove the 10 bolts and the cylinder head.
    • Discard the bolts and the cylinder head gasket.
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