How to Replace Cylinder Head on Ford, Mercury and Lincoln?

The procedure is similar for Ford Crown Victoria, Mercury Grand Marquis, Lincoln Town Car.          

 Cylinder Head

REMOVAL & INSTALLATION Details are as follows:----

NOTE

The cylinder head bolts are a torque-to-yield design and cannot be reused. Always use new cylinder head bolts for assembly.

1. If equipped with air suspension, the air suspension switch, located on the right-hand side of the luggage compartment, must be turned to the OFFposition before raising the vehicle.
2. Drain the engine cooling system.
3. Properly relieve the fuel system pressure.
4. Remove the engine.
5. Remove the bolts and the flexplate.
6. Remove the engine/transmission spacer plate.
7. Using the Engine Lifting Bracket Set, mount the engine on a suitable engine stand.
8. If equipped with cylinder block drain plugs, remove the bolts and the RH engine mount.
9. If equipped, remove the drain plugs from the engine block. Allow the coolant to completely drain. Install the drain plugs when finished. Tighten to 177 inch lbs. (20 Nm).
10. Remove the bolt and the battery cables from the engine.
11. Disconnect the EGR tube from the exhaust manifold.
12. Disconnect the 8 ignition coil electrical connectors.
13. Disconnect the 8 fuel injector electrical connectors.
14. Remove the 2 bolts and the intake manifold shield.
15. Remove the PCV tube and if equipped, disconnect the heated PCV valve electrical connector.
16. Disconnect the generator electrical connector and detach the wire harness retainer.
17. Remove the generator mounting bracket and 4 bolts.
18. Disconnect the throttle control and the Throttle Position (TP) sensor electrical connectors.
19. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
20. Disconnect the Camshaft Position (CMP) sensor electrical connector.
21. Disconnect the radio ignition interference capacitor and remove the engine control sensor wiring.
    
    
    

    

    Fig. Disconnecting the radio ignition interference capacitor
    
    
    
    

    

    Fig. Disconnecting the fuel charging wiring from the crash bracket
22. Disconnect the fuel charging wiring from the crash bracket and the wiring support bracket and remove the harness from the engine.
23. Disconnect the EGR tube nut from the EGR system module.
24. Remove the two bolts and the generator.
25. Remove the intake manifold crash bracket bolt and prevent the bolt from contacting the cylinder head with a rubber band or tie strap.
26. Remove the intake manifold crash bracket stud bolt.
27. Remove the 8 bolts and the 8 ignition coils (4 shown).
28. Remove the 2 bolts and the coolant outlet adapter.
29. Remove the thermostat.
    
    NOTE

    If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
30. Remove the 8 bolts and the intake manifold. Discard the intake manifold gaskets.
    
    NOTE

    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.
31. Clean the sealing surfaces.
32. Remove the coolant bypass tube.
    1. Remove the retaining nut.
    2. Remove the ground strap.
    3. Remove the coolant bypass tube.
       
       
       

       

       Fig. Removing the retaining nut (1), the ground strap (2) and coolant bypass tube (3)
33. Loosen the studs and bolts and remove the LH valve cover. Clean the mating surface and discard gasket.
34. Loosen the studs and bolts and remove the RH valve cover. Discard the gasket.
    
    NOTE

    Only use hand tools when removing or installing the spark plugs, damage may occur to the cylinder head or spark plug.
    
    
    
    NOTE

    Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs.
35. Remove the spark plugs.
36. Position the lobe of the camshaft upward.
37. Install the Valve Spring Compressor Spacer between the valve spring coils to prevent valve stem seal damage.
    
    NOTE

    If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage.
38. Using the Valve Spring Compressor, compress the valve springs and remove the camshaft roller followers.
    
    NOTE

    If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage.
39. Remove the 16 hydraulic lash adjusters.
40. Remove the bolt and the belt idler pulley.
41. Remove the A/C compressor pump pulley.
42. Remove the crankshaft pulley bolt.
43. Using the Crankshaft Vibration Damper Remover, remove the crankshaft pulley.
44. Using the Crankshaft Front Oil Seal Remover, remove the crankshaft front oil seal.
45. Remove the front 4 oil pan bolts.
    
    NOTE

    Correct fastener location is essential for the installation. Record fastener location.
46. Remove the engine front cover in sequence from the cylinder block. Discard the gaskets.
47. Remove the crankshaft sensor ring.
48. Position the crankshaft with the keyway at the 12 o'clock position.
49. 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.
50. Remove the LH and RH timing chains and the crankshaft sprocket.
    1. Remove the RH timing chain from the camshaft sprocket.
    2. Remove the RH timing chain from the crankshaft sprocket.
    3. Repeat for the LH timing chain and crankshaft sprocket.
51. Remove both 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.
52. Remove the RH exhaust manifold.
    1. Remove the nuts and discard.
    2. Remove the RH exhaust manifold.
    3. Remove and discard the RH exhaust manifold gasket.
    4. Remove and discard the 8 RH exhaust manifold studs.
53. Remove the LH exhaust manifold.
    1. Remove the nuts and discard.
    2. Remove the LH exhaust manifold.
    3. Remove and discard the LH exhaust manifold gaskets.
54. Remove and discard the 8 LH exhaust manifold studs.
55. Remove the bolt and the oil level indicator tube.
56. Remove the cylinder head insert from the LH cylinder head.
    
    
    

    

    Fig. Removing the cylinder head insert from the LH cylinder head
57. Clean and inspect the exhaust manifolds.
58. Install the Cylinder Head Remover/Installer on both ends of the cylinder head.
    
    NOTE

    The cylinder head must be cool before removing it from the engine. Cylinder head warpage may result if a warm or hot cylinder head is removed.
    
    
    
    NOTE

    Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface. The scratches may cause leak paths.
    
    
    
    NOTE

    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

    Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.
    
    
    
    NOTE

    The cylinder head bolts must be discarded and new bolts installed. They are a tighten-to-yield design and cannot be reused.
59. Remove the bolts and the LH cylinder head. Discard the cylinder head gasket. Discard the cylinder head bolts.
    
    NOTE

    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

    Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.
    
    
    
    NOTE

    If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.
    
    
    
    
    

    

    Fig. Identifying the cylinder head bolts-RH side shown, LH similar
60. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block in the following sequence.
    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.
61. Support the cylinder heads on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion, paying particular attention to the oil pressure feed area.
    
    
    

    

    Fig. Locating the oil pressure feed areas-LH side shown, RH similar

To install:

NOTE

The gasket sealing surfaces on the cylinder head and cylinder block must be clean.

NOTE

The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.

NOTE

The new gasket has a film coating which is crucial to the gasket's ability to seal correctly. Do not scratch the gasket.

NOTE

Cylinder head machining or milling is not authorized by the Ford Motor Company. Cylinder head flatness must be within 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area.

NOTE

The gasket sealing surfaces on the cylinder head and cylinder block must be clean.

NOTE

The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.

NOTE

Do not allow the dowels to scratch the sealing surface of the cylinder head during cylinder head installation.

1. Install the cylinder head on the dowels and the head gasket. Loosely install new bolts.
2. Tighten the cylinder head bolts in 6 stages, in the sequence shown.
   1. Stage 1: Tighten to 30 ft. lbs. (40 Nm).
   2. Stage 2: Tighten an additional 90 degrees (one-quarter turn).
   3. Stage 3: Loosen a minimum of one full turn (360 degrees).
   4. Stage 4: Tighten to 30 ft. lbs. (40 Nm).
   5. Stage 5: Tighten an additional 90 degrees (one-quarter turn).
   6. Stage 6: Tighten an additional 90 degrees (one-quarter turn).
      
      
      

      

      Fig. Cylinder head torque sequence
3. Remove the Cylinder Head Remover/Installer from both ends of the cylinder head.
   
   NOTE

   Lubricate the O-ring seal with clean engine oil.
4. For the LH cylinder head:
   1. Install a new O-ring seal on the oil level indicator tube and install the oil level indicator tube and bolt. Tighten to 89 inch lbs. (10 Nm).
   2. Install the 8 new LH exhaust manifold studs. Tighten to 106 inch lbs. (12 Nm).
   3. Install a new LH exhaust manifold gasket the LH exhaust manifold and 8 new nuts. Tighten to 177 inch lbs. (20 Nm) in sequence.
5. For RH cylinder head :
   1. Install the 8 new RH exhaust manifold studs. Tighten to 106 inch lbs. (12 Nm).
   2. Install a new RH exhaust manifold gasket the RH exhaust manifold and 8 new nuts. Tighten to 177 inch lbs. (20 Nm).
6. Engines with ratcheting timing chain tensioners
   
   NOTE

   Timing chain procedures must be followed exactly or damage to valves and pistons will result.
   
   
   
   NOTE

   Do not compress the ratchet assembly. This will damage the ratchet assembly.
   
   
   1. Compress each tensioner plunger, using an edge of a vise.
   2. Using a small screwdriver or pick, push back and hold the ratchet mechanism.
   3. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
   4. Install a paper clip into the hole of each tensioner housing to hold the ratchet assembly and plunger in during installation.
   5. Remove the tensioner from the vise.
7. Engines with non-ratcheting timing chain tensioners.
   
   NOTE

   If one or both 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 or engine damage may occur.
   
   
   1. Inspect the RH and LH timing chain tensioners. Install new tensioners as necessary.
      
      CAUTION

      Timing chain procedures must be followed exactly or damage to valves and pistons will result.
   2. Compress each tensioner plunger, using an edge of a vise.
   3. Install a Hydraulic Chain Tensioner Retaining Clip on the tensioner to hold the plunger in during installation.
8. For both cylinder heads: If the colored links are not visible, mark one link on one end and one link on the other end, and use as timing marks.
9. Using the Crankshaft Holding Tool, position the crankshaft. Remove the Crankshaft Holding Tool after crankshaft positioning.
10. Install the crankshaft sprocket, making sure the flange faces forward.
11. Install the timing chain guides.
    1. Position the LH timing chain guide.
    2. Install and tighten the LH bolts to 89 inch lbs. (10 Nm).
    3. Position the RH timing chain guide.
    4. Install and tighten the RH bolts to 89 inch lbs. (10 Nm).
12. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 1 o'clock position.
13. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the colored (marked) link with the timing mark on the sprocket.
14. Install the LH timing chain on the camshaft sprocket, aligning the colored (marked) link with the timing marks on the sprocket.
    
    NOTE

    The LH timing chain tensioner arm has a bump near the dowel hole for identification.
15. Position the LH timing chain tensioner on the dowel pin and install the LH timing chain tensioner. Tighten to 18 ft. lbs. (25 Nm).
16. Remove the Hydraulic Chain Tensioner Retaining Clip from the LH timing chain tensioner.
17. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the colored (marked) link with the timing mark on the sprocket.
18. Install the RH timing chain on the camshaft sprocket, aligning the colored (marked) link with the timing marks on the sprocket
19. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner. Tighten to 18 ft. lbs. (25 Nm).
20. Remove the Hydraulic Chain Tensioner Retaining Clip from the RH timing chain tensioner.
21. Make sure that the colored (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.
22. Rotate the camshaft until the lobe is in the upward position.
23. Install the Valve Spring Compressor Spacer between the valve spring coils to prevent valve stem seal damage.
    
    NOTE

    Lubricate the hydraulic lash adjusters with clean engine oil.
24. Install the 16 hydraulic lash adjusters in their original locations (4 shown).
    
    NOTE

    Lubricate the camshaft roller followers using clean engine oil. Position the cam lobe away from the camshaft roller follower location prior to installing each camshaft roller follower.
25. Install the camshaft roller follower.
    1. Install the Valve Spring Compressor.
    2. Compress the valve spring.
    3. Install the camshaft roller followers in their original locations.
26. Remove the Valve Spring Compressor Spacer.
    
    NOTE

    Only use hand tools when removing or installing the spark plugs, damage may occur to the cylinder head or spark plug.
27. Install all 8 spark plugs.
28. Install the crankshaft sensor ring.
    
    NOTE

    If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
29. Apply a bead of sealant along the head-to-block surface and the oil pan-to-block surface as specified.
30. Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the fasteners finger-tight.
31. Tighten the front cover fasteners in sequence to 18 ft. lbs. (25 Nm).
32. Loosely install the 4 bolts, then tighten in 2 stages in sequence.
    1. Stage 1: Tighten to 15 ft. lbs. (20 Nm).
    2. Stage 2: Tighten an additional 60 degrees.
33. Install the RH and LH engine mounts and the bolts. Tighten to 52 ft. lbs. (70 Nm).
34. Lubricate the engine front cover and the front oil seal inner lip with clean engine oil.
35. Using the Crankshaft Front Oil Seal Installer, Front Cover Oil Seal Installer and Crankshaft Vibration Damper Installer, install the front oil seal.
    
    NOTE

    If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
36. Apply sealant to the Woodruff key slot on the crankshaft pulley.
37. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
    
    NOTE

    Use a Strap Wrench to hold the pulley.
38. Tighten the crankshaft pulley bolt in 4 stages.
    1. Stage 1: Tighten to 89 ft. lbs. (120 Nm).
    2. Stage 2: Loosen 360 degrees.
    3. Stage 3: Tighten to 37 ft. lbs. (50 Nm).
    4. Stage 4: Rotate an additional 90 degrees (one-quarter turn).
    5. Position the coolant pump pulley on the coolant pump and install the bolts. Tighten to 18 ft. lbs. (25 Nm).
39. Install the accessory drive belt idler pulley and bolt. Tighten to 18 ft. lbs. (25 Nm).
    
    NOTE

    If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
40. Apply sealant in 2 places where the engine front cover meets the cylinder head.
41. Install the new valve cover gasket into the valve cover and position on the cylinder head. Tighten the bolts in sequence. Tighten to 89 inch lbs. (10 Nm).
    
    NOTE

    If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
42. Apply sealant in 2 places where the engine front cover meets the cylinder head.
43. Install the gasket into the valve cover and position on the cylinder head. Tighten the bolts in sequence. Tighten to 89 inch lbs. (10 Nm).
44. Inspect the O-ring seals. Install new seals if necessary.
45. Install the coolant bypass tube.
46. Install the ground strap on the rear of the RH cylinder head.
    1. Install the stud bolt and tighten to 18 ft. lbs. (25 Nm).
    2. Install the ground strap.
    3. Install the retaining nut and tighten to 89 inch lbs (10 Nm).
47. Install the insert into the LH cylinder head.
    
    NOTE

    If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
    
    
    
    NOTE

    Align the gasket locator tabs to slots in cylinder head.
48. Install the new intake manifold gaskets, intake manifold and hand-tighten the bolts.
49. Install the 8 ignition coils and tighten the 8 bolts (4 shown). Tighten to 53 inch lbs. (6 Nm).
50. Install the intake manifold bracket and loosely install the bolt and the stud bolt.
51. Install the thermostat.
52. Install the coolant outlet adapter and loosely install the 2 bolts. Tighten the bolts in sequence. Tighten to 18 ft. lbs. (25 Nm).
53. Tighten the stud bolt to 18 ft. lbs. (25 Nm).
54. Tighten the bolts to 18 ft. lbs. (25 Nm).
55. Connect the EGR tube to the EGR valve. Tighten to 32 ft. lbs. (43 Nm).
56. Connect the EGR tube-to-exhaust manifold connector. Tighten to 32 ft. lbs. (43 Nm).
57. Position the fuel charging wiring at 2 locations at the back of the intake manifold.
58. Install the generator and the 2 bolts. Tighten to 18 ft. lbs. (25 Nm).
59. Connect the throttle control and the Throttle Position (TP) sensor electrical connector.
60. Install the generator mounting bracket and the 4 bolts. Tighten to 89 inch lbs (10 Nm).
61. Attach the wire harness retainer and connect the generator electrical connector.
62. Connect the electrical connector to the EGR vacuum regulator solenoid.
63. Connect the crankcase ventilation tube and if equipped, the heated PCV valve electrical connector.
64. Install the intake manifold shield and the 2 bolts. Tighten to 89 inch lbs (10 Nm).
65. Connect the 8 fuel injector electrical connectors.
66. Connect the 8 ignition coil electrical connectors.
67. Connect the Camshaft Position (CMP) sensor electrical connector.
68. Connect the radio interference capacitor electrical connector.
69. Connect the Cylinder Head Temperature (CHT) sensor electrical connector.
70. Install the battery cables and the bolt.
71. Install the Engine Lifting Bracket to the RH cylinder head.
72. Install the Engine Lifting Bracket to the LH cylinder head.
73. Using the Engine Lifting Bracket Set, remove the engine from the engine stand.
74. Install the engine/transmission spacer plate.
75. Position the flexplate and install the bolts in the sequence shown. Tighten to 59 ft. lbs. (80 Nm).
76. Install the engine.
77. Connect the negative battery cable.
78. Fill the cooling system.
79. If equipped with air suspension, turn the air suspension switch to the ONposition.
80. Refill the engine with the correct amount of oil and replace the filter.
81. Start the engine and bring to normal operating temperature while checking for leaks.
82. Road test the vehicle and check for proper engine operation.

This details will help.

Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html