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Home >> Mercury >> 2008 >> Milan Base, 3.0 1, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 5 (Engine - 2.3L) >> In-Vehicle Servicing >> Cylinder Head >> Removal

Cylinder Head: Removal

WARNING: This page is about a different variant/trim than selected.
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 can cause engine failure.

All vehicles 

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING article.
  2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
  3. Check the valve clearance. For additional information, refer to Valve Clearance Check .
  4. Remove the degas bottle. For additional information, refer to ENGINE COOLING article.
  5. Remove the catalytic converter. For additional information, refer to EXHAUST SYSTEM article.
  6. Remove the generator. For additional information, refer to CHARGING SYSTEM - GENERAL INFORMATION article.
  7. Remove the fuel supply rail. For additional information, refer to FUEL CHARGING AND CONTROLS - 2.3L article.
  8. Remove the intake manifold. For additional information, refer to Intake Manifold .

    9. Vehicles with Secondary Air Injection (AIR) 

  9. Disconnect the Secondary Air Injection (AIR) pump electrical connector.
  10. Remove the 3 bolts and position the AIR pump aside.

    11. All vehicles 

  11. Remove the bolt and the radio frequency interference capacitor from the engine mount bracket.
  12. Remove the engine mount bracket bolt.
  13. Install the Engine Lifting Brackets and a suitable length of chain to the threaded hole in the LH side of the engine block.
    14. Fig 1: Identifying Special Tool (303-050)
    GF0028737Courtesy of FORD MOTOR CO.
  14. Using the Engine Support Bar and Engine Lifting Brackets, lift the engine 25 mm (0.98 in).
    15. Fig 2: Lifting Engine Using Special Tool (303-050, 313-F072)
    GF0028738Courtesy of FORD MOTOR CO.
  15. Remove the nut, 2 bolts and the engine mount.
  16. Lower the engine 25 mm (0.98 in).
  17. Remove the 2 nuts and the engine mount bracket.
  18. Remove the timing drive components. For additional information, refer to Timing Drive Components .
  19. Remove the Camshaft Alignment Plate.
    20. Fig 3: Identifying Special Camshaft Tool (303-465)
    G03898006Courtesy of FORD MOTOR CO.
  20. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.
    21. Fig 4: Locating Camshaft Lobe
    G03898791Courtesy of FORD MOTOR CO.
  21. Remove the bolt and the Variable Camshaft Timing (VCT) solenoid.
    22. 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.
  22. Remove the camshafts from the engine.
    • Loosen the camshaft bearing cap bolts, in the sequence shown, 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.
    23. Fig 5: Identifying Loosening Sequence Of Camshaft Bearing Cap Bolts
    GF0028726Courtesy 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.
    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.
  23. Remove and inspect the valve tappets. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
  24. Detach the retaining clip and position the Evaporative Emission (EVAP) tube bundle aside.
    25. Fig 6: Locating Evaporative Emissions (EVAP) Tube Bundle Retaining Clip
    GF0028739Courtesy of FORD MOTOR CO.
  25. Disconnect the upper radiator hose, coolant bypass hose, heater hose and coolant vent hose from the engine coolant outlet.
  26. Disconnect the engine Engine Coolant Temperature (ECT) electrical connector.
  27. Disconnect the EGR valve electrical connector.
  28. Disconnect the coolant hose from the EGR valve.

    29. Vehicles with AIR 

  29. Remove the 2 bolts and position the AIR valve bracket aside.

    30. All vehicles 

  30. Remove the 10 bolts and the cylinder head.
    • Discard the bolts.
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