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Home >> Ford >> 2020 >> Fusion Titanium Hybrid >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 37 (Engine - 1.5L ECOBOOST (118KW/160PS) - I4) >> Removal And Installation >> Cylinder Head >> Removal

Cylinder Head: Removal

WARNING: This page is about a different variant/trim than selected.
  1. With the vehicle in NEUTRAL, position it on a hoist. Refer to: Jacking and Lifting - Overview .
  2. Release the fuel system pressure. Refer to: Fuel System Pressure Release .
  3. Disconnect the battery ground cable. Refer to: Battery Disconnect and Connect .
  4. Remove the following items:

    1. Remove the CAC intake pipe. Refer to: Charge Air Cooler (CAC) Intake Pipe .
    2. Remove the EVAP canister purge valve. Refer to: Evaporative Emission Canister Purge Valve .

  5. Drain the cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .
  6. Remove and discard the halfshaft bearing retaining nuts and strap.
    GFD479410Courtesy of FORD MOTOR COMPANY
  7. NOTE: It may be necessary to rotate the halfshaft to remove the front lower bolt.

    Remove the bolts and position the halfshaft bearing bracket aside.

    GFD479411Courtesy of FORD MOTOR COMPANY
  8. Remove the engine plug bolt.
    GFD479412Courtesy of FORD MOTOR COMPANY
  9. Loosen the coolant pump pulley bolts.
    GFD479413Courtesy of FORD MOTOR COMPANY
  10. Disconnect the CKP sensor electrical connector and wire harness retainers.
    GFD479414Courtesy of FORD MOTOR COMPANY
  11. If equipped, remove the retainers and the heat shield.
    GFD479415Courtesy of FORD MOTOR COMPANY
    • Disconnect the turbocharger hose and the retainers. Use the General Equipment: Hose Clamp Remover/Installer

    • Disconnect the electrical connectors from the bracket.

    GFD479416Courtesy of FORD MOTOR COMPANY
  13. Disconnect the CHT sensor electrical connector.
    GFD479417Courtesy of FORD MOTOR COMPANY
  14. Remove the following items:

    1. Remove the High-Pressure fuel pump drive unit. Refer to: High-Pressure Fuel Pump Drive Unit .
    2. Remove the brake vacuum pump. Refer to: Brake Vacuum Pump - 1.5L EcoBoost (118kW/160PS) - I4 .

  15. Disconnect the PCM electrical connector.
    GFD479418Courtesy of FORD MOTOR COMPANY
  16. Detach the wiring harness retainer, disconnect the electrical connector and position the wiring harness aside.
    GFD479419Courtesy of FORD MOTOR COMPANY
  17. Remove the wiring harness bolt. Detach the wire harness retainer and position the wire harness aside.
    GFD479420Courtesy of FORD MOTOR COMPANY
  18. Disconnect the IAT sensor electrical connector and the wire harness retainer.
    GFD479421Courtesy of FORD MOTOR COMPANY
    1. Disconnect and position aside the coolant tube.
    2. Detach and disconnect the KS electrical connector.
    3. Detach and disconnect the KS electrical connector.
    GFD479422Courtesy of FORD MOTOR COMPANY
  20. Disconnect the TB (throttle body) electrical connector and the wire harness retainer.
    GFD479423Courtesy of FORD MOTOR COMPANY
  21. Disconnect the quick release couplings and position the coolant hoses aside.
    GFD479424Courtesy of FORD MOTOR COMPANY
  22. Disconnect the wire harness retainers.
    GFD479425Courtesy of FORD MOTOR COMPANY
  23. Disconnect the retainer from the coolant tube bracket.
    GFD479426Courtesy of FORD MOTOR COMPANY
  24. Remove the retainers for the turbocharger coolant tubes.
    GFD479427Courtesy of FORD MOTOR COMPANY
  25. Remove the bolt and position aside the turbocharger cooling tubes.
    GFD479428Courtesy of FORD MOTOR COMPANY
  26. Remove and discard the turbocharger coolant tube O-ring seals.
    GFD479429Courtesy of FORD MOTOR COMPANY
  27. Remove the bolts and turbocharger heat shield.
    GFD479430Courtesy of FORD MOTOR COMPANY
  28. Remove the TC oil supply tube bolt and disconnect from the engine.
    GFD479431Courtesy of FORD MOTOR COMPANY
  29. Remove and discard the TC oil supply tube assembly.
    GFD479432Courtesy of FORD MOTOR COMPANY
  30. NOTE: The turbocharger is left in place during the cylinder head procedure.

    Remove and discard the TC nuts.

    GFD479433Courtesy of FORD MOTOR COMPANY
  31. Remove and discard the TC mounting studs and the gasket.
    GFD479434Courtesy of FORD MOTOR COMPANY
  32. Disconnect the coolant hose and position aside. Use the General Equipment: Hose Clamp Remover/Installer
    GFD479435Courtesy of FORD MOTOR COMPANY
    1. Remove the nut.
    2. Remove the stud and position out the coolant outlet.
    GFD479436Courtesy of FORD MOTOR COMPANY
  34. Inspect the coolant outlet O-ring seal and replace if damaged.
    GFD479437Courtesy of FORD MOTOR COMPANY
  35. Remove the TB (throttle body). Refer to: Throttle Body .
  36. Remove the bolts and the intake manifold bracket.
    GFD479438Courtesy of FORD MOTOR COMPANY
  37. Disconnect and remove the engine vent hose. Use the General Equipment: Hose Clamp Remover/Installer
    GFD479439Courtesy of FORD MOTOR COMPANY
  38. NOTE: The bolt is captured in the oil separator tube.

    Loosen the bolt for the oil separator tube.

    GFD479440Courtesy of FORD MOTOR COMPANY
  39. NOTE: The bolt is captured in the intake manifold.

    • Loosen the bolt for the intake manifold.

    • Using a tie strap or rubber band, secure the intake manifold bolt in the removed position.

    GFD479441Courtesy of FORD MOTOR COMPANY
  40. Remove the following items:

    1. Remove the engine mount. Refer to: Engine Mount .
    2. Remove the accessory drive belt. Refer to: Accessory Drive Belt .

  41. Remove the bolts and the coolant pump pulley.
    GFD479442Courtesy of FORD MOTOR COMPANY
    1. Remove the upper generator mounting stud bolt and if equipped, the bracket.
    2. Remove the generator mounting nut.
    Fig 1: Generator Mounting Nut Loosening Sequence
    GFD479443Courtesy of FORD MOTOR COMPANY
  43. Remove the generator stud.
    GFD479444Courtesy of FORD MOTOR COMPANY
  44. Loosen the bolt and position out the generator.
    GFD479445Courtesy of FORD MOTOR COMPANY
  45. Remove the engine mount stud.
    GFD479446Courtesy of FORD MOTOR COMPANY
  46. Remove the nut, the bolt and the bracket.
    GFD479447Courtesy of FORD MOTOR COMPANY
    1. Remove the timing cover stud bolt.
    2. Detach the cover from the retainer and open.
    GFD479448Courtesy of FORD MOTOR COMPANY
  48. Remove the engine front cover bolts.
    Fig 2: Engine Front Cover Bolts Loosening Sequence
    GFD479449Courtesy of FORD MOTOR COMPANY
  49. Remove the engine front cover.
    GFD479450Courtesy of FORD MOTOR COMPANY
  50. NOTE: Timing belt removal is only necessary if a new timing belt is being installed.

    Install a new timing belt if the existing belt is contaminated by coolant or oil. Refer to: Timing Belt .

    GFD479451Courtesy of FORD MOTOR COMPANY
  51. NOTE: Note the different lengths of the bolts for installation.

    Remove the bolts and the engine mount bracket.

    GFD479452Courtesy of FORD MOTOR COMPANY
  52. NOTE: Only rotate the crankshaft in a clockwise direction.

    Rotate the crankshaft slowly until the 11 o'clock position.

    GFD479453Courtesy of FORD MOTOR COMPANY
  53. NOTE: The Crankshaft TDC Timing Pin will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during the crankshaft pulley removal and installation.

    Install Special Service Tool: 303-748 Locking Tool, Crankshaft.

    GFD479454Courtesy of FORD MOTOR COMPANY
  54. NOTE: Only rotate the crankshaft in a clockwise direction.

    Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at TDC.

    GFD479455Courtesy of FORD MOTOR COMPANY
    • Install Special Service Tool: 303-1556 Locking Tool, Timing Belt.

    • Mark the position of the components before removal.

    GFD479456Courtesy of FORD MOTOR COMPANY
  56. NOTE: Do not rotate the crankshaft or camshafts while the timing belt is removed.

    1. Rotate the timing belt tensioner.
    2. General Equipment: Holding Pin Install a holding pin.
    3. Carefully remove the timing belt from the VCT units.

    GFD479457Courtesy of FORD MOTOR COMPANY
  57. Remove the camshaft seals. Refer to: Camshaft Seal .
  58. NOTE: Use a heat gun to soften the flange sealant, this will aid in the removal of the camshaft mega cap. Failure to follow these directions may result in damage to the camshaft mega cap.
    NOTE: Do not pry on camshafts when removing or damage to the camshafts may occur.
    NOTE: Note the location and orientation of each camshaft bearing cap and the position of the camshaft lobes on the No. 1 cylinder for installation reference.
    NOTE: Discard the 4 mega cap bolts and 8 of the camshaft bearing cap bolts, 8 of the camshaft bearing cap bolts will be used to hold camshafts and valve tappets in place and will be discarded later in this procedure.

    • Remove the 20 bolts.

    • Remove the camshaft caps.

    • Heat and remove the mega cap. Use the General Equipment: Hot Air Gun

    • Remove the camshafts.

    Fig 3: Cylinder Head Bolts Loosening Sequence
    GFD479458Courtesy of FORD MOTOR COMPANY
  59. Remove the crankcase vent oil drain tube.
    GFD479459Courtesy of FORD MOTOR COMPANY
  60. Inspect crankcase vent oil drain tube and replace if damaged.
    GFD479460Courtesy of FORD MOTOR COMPANY
  61. Remove and discard the O-ring seal.
    GFD479461Courtesy of FORD MOTOR COMPANY
  62. Make sure that the mating faces are clean and free of foreign material.
    GFD479462Courtesy of FORD MOTOR COMPANY
  63. Make sure that the mating faces are clean and free of foreign material.
    GFD479463Courtesy of FORD MOTOR COMPANY
  64. NOTE: Make sure that the cylinder head is at ambient air temperature before removing the cylinder head bolts.

    Remove and discard the cylinder head bolts.

    Fig 4: Cylinder Head Bolts Loosening Sequence
    GFD479464Courtesy of FORD MOTOR COMPANY
  65. NOTE: If any new parts are being installed (cylinder head, valves, tappets, camshafts) it is necessary to check the valve clearance. If the original parts are being installed it is not necessary to check the valve clearance.
    NOTE: The camshafts are installed to keep the valve tappets in place during cleaning.

    Position the camshafts in the neutral position in the cylinder head. Install the 4 camshaft caps and the 8 original bolts. Tighten the camshaft bearing cap bolts 1 turn at a time until seated against the cylinder head.

    GFD479465Courtesy of FORD MOTOR COMPANY
  66. NOTE: Note the routing of the KS (knock sensor) wiring before removal of the cylinder head.

    Remove the cylinder head.

    GFD479466Courtesy of FORD MOTOR COMPANY
  67. Remove and discard the cylinder head gasket.
    GFD479467Courtesy of FORD MOTOR COMPANY
  68. NOTE: Support the cylinder head on a bench with the head gasket side up.

    Inspect the cylinder head and cylinder block distortion. Refer to: Cylinder Head Distortion . Refer to: Cylinder Block Distortion .

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