Cylinder Head - 4.6L: Removal

All cylinder heads 

1. Remove the engine. For additional information, refer to Engine .
CAUTION: Use care when lowering the engine, to prevent damage to the oil pan.
2. Lower the engine onto wooden blocks.
3. Remove the special tool.
Fig 1: Identifying Special Tool (303-F047)
Courtesy of FORD MOTOR CO.
4. Install the special tool.
Fig 2: Special Tool (303-D087)
Courtesy of FORD MOTOR CO.
5. Install the special tool.
Fig 3: Special Tool (303-D088)
Courtesy of FORD MOTOR CO.
6. Mount the engine on a suitable work stand.
7. Remove the 3 bolts and the RH engine support insulator.
Fig 4: RH Engine Support Insulator Bolts
Courtesy of FORD MOTOR CO.
NOTE: LH shown, RH similar.
8. Remove the cylinder block drain plugs and drain the coolant in a suitable container.
Fig 5: Locating Cylinder Block Drain Plug
Courtesy of FORD MOTOR CO.
9. Disconnect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
Fig 6: Locating LH Radio Ignition Interference Capacitor And Cylinder Head Temperature (CHT) Sensor Electrical Connectors
Courtesy of FORD MOTOR CO.
10. Disconnect the camshaft position (CMP) sensor electrical connector.
Fig 7: Locating Camshaft Position (CMP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
11. Disconnect the RH radio frequency interference capacitor electrical connector.
Fig 8: Locating RH Radio Ignition Interference Capacitor Electrical Connector
Courtesy of FORD MOTOR CO.
12. Disconnect the knock sensor (KS) electrical connector.
Fig 9: Knock Sensor (KS) Electrical Connector
Courtesy of FORD MOTOR CO.
13. Disconnect the crankshaft position (CKP) sensor electrical connector.
Fig 10: Identifying Crankshaft Position Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
14. Disconnect the engine oil pressure (EOP) switch electrical connector.
Fig 11: Locating Oil Pressure Switch Electrical Connector
Courtesy of FORD MOTOR CO.
15. Disconnect all of the harness routing clips and connector retainers. Remove the engine control sensor wiring harness.
NOTE: RH shown, LH similar.
16. Remove the 2 nuts and the 2 radio interference capacitors.
Fig 12: Radio Interference Capacitor And Retaining Nut
Courtesy of FORD MOTOR CO.
17. Remove the oil level indicator tube support bracket nut.
Fig 13: Oil Level Indicator Tube Support Bracket Nut
Courtesy of FORD MOTOR CO.
18. Remove the bolt and the oil level indicator and tube.
    • Discard the O-ring seal.
Fig 14: Oil Level Indicator Tube Retaining Bolt
Courtesy 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 which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
NOTE: The fasteners are part of the valve cover and should not be removed.
NOTE: LH shown, RH similar.
19. Remove the valve covers.
    • Fully loosen the fasteners and remove the valve covers.
    • Clean the valve cover mating surface of the cylinder heads with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
Fig 15: Locating Valve Cover
Courtesy of FORD MOTOR CO.
20. Remove the bolt and the accessory drive belt idler pulley.
Fig 16: Accessory Drive Belt Idler Pulley And Retaining Bolt
Courtesy of FORD MOTOR CO.
21. Remove the 4 bolts and the coolant pump pulley.
Fig 17: Identifying Coolant Pump Pulley Bolts
Courtesy of FORD MOTOR CO.
22. Remove the crankshaft pulley bolt and washer.
    • Discard the crankshaft pulley bolt.
23. Using the special tool, remove the crankshaft pulley.
Fig 18: Removing Crankshaft Pulley Using Special Tool
Courtesy of FORD MOTOR CO.
24. Using the special tool, remove and discard the crankshaft front seal.
Fig 19: Removing Crankshaft Front Seal Using Special Tool
Courtesy of FORD MOTOR CO.
25. Remove the 3 bolts and the power steering pump.
Fig 20: Power Steering Pump Bolts
Courtesy of FORD MOTOR CO.
26. Remove the 4 front oil pan bolts.
Fig 21: Front Oil Pan Bolts
Courtesy of FORD MOTOR CO.
NOTE: Correct fastener location is essential for assembly procedure. Record fastener location.
27. Remove the fasteners.
Fig 22: Front Cover Bolts
Courtesy of FORD MOTOR CO.
28. Remove the engine front cover from the cylinder block.
Fig 23: Removing Engine Front Cover From Cylinder Block
Courtesy of FORD MOTOR CO.
29. Remove the crankshaft sensor ring from the crankshaft.
Fig 24: View Of Crankshaft Sensor Ring At Crankshaft
Courtesy of FORD MOTOR CO.
30. Remove the 8 spark plugs. For additional information, refer to ENGINE IGNITION - 4.6L (2V) AND 5.4L (2V) article.
NOTE: Camshaft roller follower is removed for clarity.
31. Install the special tool between the valve spring coils to prevent valve stem seal damage.
Fig 25: Installing Special Tool Between Valve Spring Coils
Courtesy of FORD MOTOR CO.
CAUTION: The camshaft roller followers must be reinstalled in their original locations. Record the camshaft roller follower locations. Failure to follow these instruction may result in engine damage.
NOTE: Position the cam lobe away from the camshaft roller follower prior to removing each camshaft roller follower.
32. Use the special tool to compress the valve springs and remove the all of the camshaft roller followers.
Fig 26: Compressing Valve Springs Using Special Tool (303-567)
Courtesy of FORD MOTOR CO.
33. Position the crankshaft with the keyway at the 12 o'clock position.
Fig 27: Crankshaft With Keyway At 12 O'clock Position
Courtesy of FORD MOTOR CO.
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. Failure to follow these instructions may result in engine damage.
34. 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 28: Identifying Timing Chain Tensioning System
Courtesy of FORD MOTOR CO.
35. Remove the timing chains and crankshaft sprocket.
Fig 29: View Of Left And Right Timing Chains, Sprockets And Crankshaft Gear
Courtesy of FORD MOTOR CO.
36. Remove the timing chain guides.
    1. Remove the bolts.
    2. Remove the LH timing chain guide.
    3. Remove the bolts.
    4. Remove the RH timing chain guide.
Fig 30: Identifying Timing Chain Guides
Courtesy of FORD MOTOR CO.

RH cylinder head 

37. Remove the RH exhaust manifold.
    1. Remove and discard the nuts.
    2. Remove the RH exhaust manifold.
    3. Remove and discard the RH exhaust manifold gasket.
Fig 31: Exhaust Manifold, Nuts & Gasket
Courtesy of FORD MOTOR CO.
38. Remove and discard the 8 exhaust manifold-to-cylinder head studs.
39. Clean and inspect the exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.

LH cylinder head 

40. Remove and discard the LH exhaust manifold.
    1. Remove the nuts.
    2. Remove the LH exhaust manifold.
    3. Remove and discard the LH exhaust manifold gasket.
Fig 32: Exhaust Manifold, Nuts & Gasket
Courtesy of FORD MOTOR CO.
41. Remove and discard the 8 exhaust manifold-to-cylinder head studs.
42. Clean and inspect the exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.

All cylinder heads 

43. Install the special tools on both ends of the cylinder head being serviced.
Fig 33: Identifying Special Tool (303-572)
Courtesy of FORD MOTOR CO.
CAUTION: The hydraulic lash adjusters must be reinstalled in their original locations. Record the hydraulic lash adjuster locations. Failure to follow these instructions may result in engine damage.
44. Remove the hydraulic lash adjusters.
Fig 34: Locating Hydraulic Lash Adjusters
Courtesy of FORD MOTOR CO.
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. Failure to follow these instructions may result in engine damage.
CAUTION: The cylinder head bolts must be discarded and new bolts must be installed. They are tighten-to-yield designed and cannot be reused. Failure to follow these instructions may result in engine damage.
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.
NOTE: LH shown, RH similar.
45. Remove the bolts and the cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
Fig 35: Cylinder Head Bolts
Courtesy 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: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.
46. 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 surfaces is normal.
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, such as Snap-On® GA438A or equivalent. 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 shown, RH similar.
47. 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).
Fig 36: Identifying Cylinder Head/Cylinder Block Oil Pressure Feed Areas
Courtesy of FORD MOTOR CO.