Wednesday, June 8, 2011

How to remove Cylinder Head on ford Taurus?

REMOVAL & INSTALLATION



3.0L OHV Engines

See Figures 1 through 16



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Fig. Fig. 1: Remove the drive belt tensioner retaining bolt and...



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Fig. Fig. 2: ... remove the drive belt tensioner



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Fig. Fig. 3: Loosen and...



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Fig. Fig. 4: ... remove the power steering pump bracket mounting bolts



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Fig. Fig. 5: Carefully position the power steering pump assembly out of the way



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Fig. Fig. 6: Remove the heater hose from the bypass tube



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Fig. Fig. 7: Remove the two ignition coil bracket mounting bolts and...



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Fig. Fig. 8: ... remove the bracket from the engine



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Fig. Fig. 9: Lift the head from the engine



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Fig. Fig. 10: Remove the old head gasket from the block and...



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Fig. Fig. 11: Thoroughly clean the block-to-cylinder head mating surfaces



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Fig. Fig. 12: ALWAYS tighten the cylinder head bolts using a torque wrench and...



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Fig. Fig. 13: ... torque angle gauge (if necessary)

  1. Rotate the crankshaft until the piston in No. 1 cylinder is at TDC on the compression stroke.
  2. Disconnect the negative battery cable. Properly relieve the fuel system pressure.


CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Drain the cooling system into a suitable container.
  2. Remove the air cleaner outlet hose to throttle body.
  3. Label and disconnect the vacuum lines to the upper intake manifold.
  4. Disconnect the transducer hose from the EGR valve. Loosen the lower EGR valve-to-exhaust manifold tube nut and rotate the tube away from the valve.
  5. Label and unplug the wiring from the Intake Air Temperature (IAT) sensor, Throttle Position Sensor (TPS), Idle Air Control (IAC) valve and Pressure Feedback EGR (PFE) or Differential Pressure Feedback EGR (DPFE) sensors.
  6. Remove the fuel line safety clips and disconnect the fuel lines from the fuel supply manifold.
  7. Remove the upper intake manifold and discard the gasket.
  8. Label and disconnect the fuel injector harness from the valve cover studs and fuel injectors.
  9. Remove the ignition coil and bracket from the left (front) cylinder and set aside.
  10. Label and disconnect the ignition wires from the spark plugs and the valve cover studs.
  11. Disconnect the upper radiator and heater hoses.
  12. If necessary, remove the Camshaft Position (CMP) sensor and housing.
  13. Tag and unplug the Engine Coolant Temperature (ECT) sensor and temperature sending unit electrical connectors.
  14. For the left (front) cylinder head, perform the following:
    1. Tag and unplug the alternator electrical connectors.
    2. Rotate the tensioner clockwise and remove the accessory drive belt.
    3. Remove the automatic belt tensioner assembly.
    4. Remove the alternator and brace.
    5. Remove the power steering mounting bracket retaining bolts. Leave the hoses connected and place the pump aside in a position to prevent fluid from leaking out.
    6. Remove the engine oil dipstick tube from the exhaust manifold.

  15. For the right (rear) cylinder head, perform the following:
    1. Remove the intake manifold support.

  16. Remove the valve covers.

Regardless of the cylinder head being removed, the No. 3 cylinder intake valve pushrod must be removed to allow removal of the intake manifold.

  1. Loosen the rocker arm fulcrum bolts and remove the rocker arms, fulcrums and bolts. Keep the assemblies in order so they can be reinstalled in their original locations.
  2. Remove the pushrods and label their positions. The pushrods must be installed in their original position during reassembly.
  3. Remove the lower intake manifold.
  4. Remove the spark plugs.
  5. Remove the exhaust manifolds.
  6. Unfasten and discard the cylinder head bolts and remove the cylinder heads from the engine.
  7. Remove and discard the old cylinder head gaskets.

To install:

The cylinder head should be cleaned and inspected before installation. Refer to the appropriate portion of the engine reconditioning procedure later in this section.


CAUTION
Use care when using a scraper to clean any aluminum parts. Aluminum gouges easily which may cause the component to leak.

  1. Place a shop rag in the valve tappet valley to catch any dirt or gasket material. Clean the cylinder head bolts holes in the block with a tap. Clean the cylinder head, intake manifold, rocker arm cover and cylinder head gasket contact surfaces.
  2. Position new head gaskets on the cylinder block using the dowels in the block for alignment. If the dowels are damaged, they must be replaced.



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Fig. Fig. 14: The cylinder head dowels must be fully seated to install gasket and head properly-3.0L OHV engines

  1. Position the cylinder head on the block. Install new cylinder head bolts and tighten, in the sequence illustrated as follows:
    1. First pass: tighten the cylinder head bolts in the sequence illustrated to 52-66 ft. lbs. (70-90 Nm), then back off the bolts 360 degrees.
    2. Second pass: tighten the cylinder head bolts in the sequence illustrated to 45-55 ft. lbs. (34-40 Nm).
    3. Final pass: tighten the cylinder head bolts in the sequence illustrated to 63-73 ft. lbs. (85-99 Nm).




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Fig. Fig. 15: Cylinder head bolt tightening sequence-3.0L OHV engines



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Fig. Fig. 16: Camshaft position during rocker arm installation and valve clearance check-3.0L OHV engines

  1. Install the intake manifold.
  2. Attach the ECT and coolant temperature sending unit connectors.
  3. Dip each pushrod end in oil conditioner or heavy engine oil. Install the pushrods in their original position.
  4. Before installation, coat the valve tips, rocker arm and fulcrum contact areas with Lubriplate® or equivalent.
  5. Rotate the crankshaft one full turn (360 degrees) until the lifter is on the base circle of the cam as shown in the accompanying illustration (camshaft position A).
  6. Install the rocker arm assemblies and tighten the rocker arm fulcrum bolts to 6-11 ft. lbs. (7-17 Nm) to position the rocker arm seats.
  7. Rotate the crankshaft clockwise 120 degrees to camshaft position B as shown in the accompanying illustration. Tighten the rocker arm fulcrum bolts to 6-11 ft. lbs. (7-17 Nm) to position the rocker arm seats.

The fulcrums must be fully seated in the cylinder head and the pushrods must be seated in the rocker arm sockets prior to the final tightening.

  1. Final tighten the rocker arm fulcrum bolts to 20-28 ft. lbs. (26-38 Nm).

If the same valve train components are used a valve train check is not required. If new components were installed, measure the clearance with the valve tappet fully collapsed on the base circle of the camshaft lobe. The measurement should be 0.085-0.185 inch (2.15-4.69mm). Refer to the accompanying illustration if necessary for the valve clearance measurement.

  1. Install the lower intake manifold.
  2. Install the spark plugs.
  3. Position the valve covers on the cylinder head and install the retaining bolts. Note the location of the ignition wire retainer stud bolts.
  4. Install the fuel charging wiring to the fuel injectors and inboard valve cover stud bolts.
  5. Install the upper intake manifold upper gasket and the upper intake manifold.
  6. Install the ignition coil and bracket. Attach all sensor electrical connectors.
  7. For the left (front) cylinder head, perform the following:
    1. Connect the oil dipstick tube to the exhaust manifold stud and tighten the nut to 12-14 ft. lbs. (16-20 Nm).
    2. Install the power steering support bracket and pump. Tighten the retaining bolt to 30-45 ft. lbs. (40-55 Nm).
    3. Install the automatic belt tensioner and tighten the retaining nuts/bolt to 35 ft. lbs. (48 Nm).

  8. For the right (rear) cylinder head, install the intake manifold support.
  9. Install the alternator and brace.
  10. Install the drive belt.
  11. Connect the fuel lines.
  12. Install the CMP housing and sensor if removed.
  13. Connect the upper radiator hose and heater hoses.
  14. Connect all vacuum lines to pre-marked locations.
  15. Change the engine oil and filter.
  16. Install the air cleaner outlet tube to throttle body and engine air cleaner.
  17. Install crankcase ventilation tube to valve cover.
  18. Fill and bleed the cooling system. Connect the negative battery cable. Start the engine and check for coolant, fuel, oil, vacuum and exhaust leaks.
  19. Check and if necessary, adjust the accelerator and cruise control cables.

3.0L DOHC Engines

See Figures 17 and 18

The cylinder head bolts are a torque-to-yield design and cannot be reused. Be sure new cylinder head bolts are available before beginning this procedure.

  1. Disconnect the negative battery cable.
  2. Drain the engine coolant from the radiator and cylinder block drain plugs.
  3. Remove the engine from the vehicle and position on a suitable workstand.
  4. Remove the upper and lower intake manifolds.
  5. Remove the exhaust manifolds.
  6. Drain the engine oil and remove the oil pan.
  7. Remove the engine front cover.
  8. Remove the timing chains, camshafts and lash adjusters from both cylinder heads.
  9. Remove the EGR backpressure transducer and its mounting bracket from the rear of the right hand cylinder head.
  10. Remove the cylinder head retaining bolts from the cylinder heads in the sequence illustrated.
  11. Remove the cylinder heads and gaskets.



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Fig. Fig. 17: Cylinder head bolt loosening sequence-3.0L DOHC engine

To install:

The cylinder head should be cleaned and inspected before installation. Refer to the appropriate portion of the engine reconditioning procedure later in this section.

If the cylinder heads were removed for cylinder head gasket replacement, check the flatness of the cylinder heads and the cylinder block gasket sealing surfaces.

The right hand and left hand cylinder head gaskets are not interchangeable.

  1. Install new cylinder head gaskets onto the dowels of the cylinder block.

Left and right cylinder head gaskets are not interchangeable.

  1. Place the cylinder heads to their original positions using care not to damage the heads, block or gaskets.
  2. Be sure the cylinder heads are correctly positioned on the dowels. Lightly oil the threads of the new cylinder head retaining bolts and install into the cylinder heads.
  3. Tighten the new cylinder head retaining bolts in the sequence illustrated as follows:

    Tighten the bolts, in sequence, to 28-31 ft. lbs. (37-43 Nm)
    Rotate the bolts, in sequence, 85-95 degrees
    Loosen the bolts, in sequence, a minimum of one full turn
    Tighten the bolts, in sequence, to 28-31 ft. lbs. (37-43 Nm)
    Rotate the bolts, in sequence, 85-95 degrees
    Rotate the bolts, in sequence, an additional 85-95 degrees




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Fig. Fig. 18: Cylinder head bolt tightening sequence-3.0L DOHC engine

  1. Install the lash adjusters, camshafts and timing chains to both cylinder heads.

  1. Install the EGR backpressure transducer and bracket to the rear of the right cylinder head. Tighten the retaining bolts to 71-106 inch lbs. (8-12 Nm).
  2. Install the lash adjusters, camshafts and timing chains.
  3. Install the engine front cover and the engine oil pan.
  4. Install the exhaust manifolds.
  5. Install the lower and upper intake manifolds. Replace the engine oil filter.
  6. Install the engine assembly into the vehicle.
  7. Fill the engine with the proper amount and grade of engine oil.
  8. Fill the engine cooling system.
  9. Connect the negative battery cable. Run the engine and check for leaks. Road test the vehicle and check for proper engine operation.

3.4L DOHC Engines

See Figures 19 and 20

The cylinder head bolts are a tighten-to-yield design and cannot be reused. Be sure new cylinder head bolts are available before beginning this procedure.

  1. Disconnect the negative battery cable.


CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Drain the engine coolant from the radiator and cylinder block drain plugs.
  2. Remove the engine from the vehicle and position on a suitable workstand.
  3. Remove the upper and lower intake manifolds.
  4. Remove the exhaust manifolds.
  5. Drain the engine oil and remove the oil pan.
  6. Remove the engine front cover.
  7. Remove the timing chains and camshafts.
  8. Remove the cylinder head retaining bolts from the cylinder heads in the removal sequence illustrated.
  9. Remove the cylinder heads and gaskets.



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Fig. Fig. 19: Cylinder head bolt loosening sequence-3.4L DOHC engine

To install:

The cylinder head should be cleaned and inspected before installation. Refer to the appropriate portion of the engine reconditioning procedure later in this section.

To install:
  1. Clean the cylinder heads, intake manifolds, valve covers and the cylinder head gasket sealing surfaces on the cylinder block.

If the cylinder heads were removed for cylinder head gasket replacement, check the flatness of the cylinder heads and the cylinder block gasket sealing surfaces.

The right hand and left hand cylinder head gaskets are not interchangeable.

  1. Install new cylinder head gaskets onto the dowels of the cylinder block.
  2. Place the cylinder heads to their original positions using care not to damage the heads, block or gaskets.
  3. Be sure the cylinder heads are correctly positioned on the dowels. Lightly oil the threads of the new cylinder head retaining bolts and install into the cylinder heads.
  4. Tighten the new cylinder head retaining bolts in the sequence illustrated as follows:

    Tighten the bolts in the sequence illustrated to 20-23 ft. lbs. (27-32 Nm)
    Rotate the bolts in the sequence illustrated an additional 85-95 degrees




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Fig. Fig. 20: Cylinder head bolt tightening sequence-3.4L (DOHC) engine

  1. Install the camshafts and timing chains.
  2. Install the engine front cover.
  3. Install the engine oil pan.
  4. Install the exhaust manifolds.
  5. Install the lower and upper intake manifolds.
  6. Replace the engine oil filter.
  7. Install the engine assembly into the vehicle.
  8. Fill the engine with the proper amount and grade of engine oil. Fill the engine cooling system.
  9. Connect the negative battery cable. Run the engine and check for leaks. Road test the vehicle and check for proper engine operation.

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