Cylinder Head: Removal

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 or 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 can cause engine failure.

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
Drain the engine cooling system. For additional information, refer to ENGINE COOLING - HYBRID .
Remove the intake manifold. For additional information, refer to INTAKE MANIFOLD .
Remove the Variable Camshaft Timing (VCT) oil control solenoid. For additional information, refer to ELECTRONIC ENGINE CONTROLS - HYBRID .
Remove the timing drive components. For additional information, refer to TIMING DRIVE COMPONENTS .
Remove the Camshaft Alignment Plate.

Fig 1: Removing Camshaft Alignment Plate
Courtesy of FORD MOTOR CO.
Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.

Fig 2: Location of Camshaft Lobe Position
Courtesy of FORD MOTOR CO.

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.

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
  Courtesy of FORD MOTOR CO.

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.

Remove the valve tappets.
Inspect the valve tappets. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
Remove the catalytic converter. For additional information, refer to EXHAUST SYSTEM .
Disconnect the EGR valve electrical connector.
Disconnect the upper radiator hose, coolant bypass hose, EGR coolant hose, heater hose and coolant vent hose from the engine coolant outlet and the EGR valve.
Remove the bolts and the cylinder head.
- Discard the bolts and the cylinder head gasket.