Thursday, March 15, 2012

How to replace Cylinder Head For 4.0L Engine On Ford Mustang?

The details to replace Cylinder Head For 2010 Ford Mustang 4.0L engine and other Mustang years is as follows:----

Removal & Installation



4.0L Engine
Specific to:
Ford Mustang 2009-2010

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.

Both sides
  1. With the vehicle in NEUTRAL, position it on a hoist.
  2. Release the fuel system pressure.
  3. Drain the engine cooling system.
  4. Remove the intake manifold.
  5. Remove the hydraulic lash adjusters.
  6. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt.
RH Side
  1. Remove the 2 coolant tube bracket bolts. 
    image
    Fig. Removing the 2 coolant tube bracket bolts
  2. Disconnect the generator electrical connector, remove the nut and detach the B+ terminal. Detach the pin-type retainer.
  3. Remove the bolt and the accessory drive belt tensioner.
  4. Disconnect the heater hose from the thermostat housing.
  5. Disconnect the upper radiator hose.
  6. Position the coolant bypass hose clamp aside.
  7. Remove the 3 bolts and the thermostat housing. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector.
LH Side
  1. Remove the bolt and the oil level indicator tube.
  2. Remove the stud bolt and detach the ground strap. Position the ground strap aside.
  3. Remove the bolt and detach the power steering supply hose bracket from the Front End Accessory Drive (FEAD) bracket.

    Click image to see an enlarged view
    Fig. Removing the FEAD bracket
  4. Remove the bolt and detach the Power Steering Pressure (PSP) tube bracket from the crossmember.

    Click image to see an enlarged view
    Fig. Detaching the PSP tube bracket from the crossmember
  5. Remove the 3 bolts and the power steering pump pulley.
  6. Remove the 3 bolts, the nut and position the FEAD bracket and A/C compressor aside.
  7. Remove the bolt and detach the starter motor wiring retainer bracket.
  8. Remove the ground strap bolt and detach the wiring harness retainer from the backside of the cylinder head.
Both Sides

NOTE
It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wires.

  1. Using the Spark Plug Wire Remover, disconnect the 6 spark plug wires from the spark plugs.
  2. Remove the 4 bolts and the fuel rail and injectors.
  3. Separate the 6 fuel injectors from the fuel rail and discard the O-ring seals.
    NOTE
    LH side shown, RH side similar.
  4. Remove the 4 catalytic converter-to-manifold nuts. Discard the nuts.
    NOTE
    LH side shown, RH side similar.
  5. Remove the 12 nuts and the exhaust manifolds and gaskets. Discard the nuts and gaskets.
    NOTE
    LH side shown, RH side similar.



    Click image to see an enlarged view
    Fig. Removing the exhaust manifold nuts and gaskets (LH shown, RH similar)
  6. Remove and discard the 12 exhaust manifold studs.

    Click image to see an enlarged view
    Fig. Removing the 12 exhaust manifold studs (LH side shown, RH similar)
RH side
  1. Remove the RH side hydraulic chain tensioner. Remove and discard the washer.
  2. Install the Camshaft Sprocket Holding Tool and Adapter. Tighten the top clamp bolts to 89 inch lbs. (10 Nm).
    NOTE
    The RH camshaft sprocket bolt is a LH-threaded bolt.
  3. Using the Torque Wrench Extension with the Camshaft Sprocket Nut Socket 303-565, remove the RH camshaft bolt.
  4. Remove the RH side cassette bolt.
    NOTE
    Remove the camshaft sprocket from the timing chain to gain clearance to remove the cylinder head.


    NOTE
    Hold the timing chain and cassette with a rubber band to aid in removal and to prevent the timing chain from falling into the cylinder block.



    Click image to see an enlarged view
    Fig. Removing the RH side cassette bolt
  5. Remove the RH camshaft sprocket from the timing chain. Install a rubber band around the cassette and the timing chain.

    Click image to see an enlarged view
    Fig. Installing a rubber band around the cassette and timing chain (RH side)
LH Side
  1. Remove the LH side hydraulic chain tensioner. Remove and discard the washer.
  2. Install the Camshaft Sprocket Holding Tool and Adapter. Tighten to 89 inch lbs. (10 Nm).
  3. Remove the LH side camshaft sprocket bolt.
  4. Remove the LH side cassette bolt.
    NOTE
    Remove the camshaft sprocket from the timing chain to gain clearance to remove the cylinder head.


    NOTE
    Hold the timing chain and cassette with a rubber band to aid in removal and to prevent the timing chain from falling into the cylinder block.
  5. Remove the LH camshaft sprocket from the timing chain. Install a rubber band around the cassette and the timing chain.

    Click image to see an enlarged view
    Fig. Installing a rubber band around the cassette and timing chain (LH side)
Both Sides

NOTE
To avoid damage to the timing chain cassette, an assistant will be required to help lift the cylinder head from the vehicle.


NOTE
On the RH side, when lifting the cylinder head, be careful to avoid contacting the A/C tube.


NOTE
New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.

  1. Remove the cylinder heads. Remove the cylinder head bolts in the sequence shown. Discard all the bolts. Remove and discard the head gaskets.
    NOTE
    Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore. Failure to follow these instructions may result in engine damage.


    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 and 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.



    Click image to see an enlarged view
    Fig. Identifying the cylinder head bolt removal sequence
  2. Clean the cylinder head-to-cylinder block mating surface 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 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.
  3. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion.
To install:
  1. Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.
  2. Position the cylinder head gaskets on the block.
RH side

NOTE
To avoid damage to the timing chain cassette, an assistant will be required to help position the cylinder head in the vehicle.


NOTE
New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.

  1. Position the RH cylinder head. Install 8 new M12 bolts and tighten in the sequence shown in 2 stages.
    1. Stage 1: Tighten to 106 inch lbs. (12 Nm).
    2. Stage 2: Tighten to 18 ft. lbs. (25 Nm).

      Click image to see an enlarged view
      Fig. Identifying the RH cylinder head M12 bolt tightening sequence
  2. Install 2 new M8 bolts. Tighten to 24 ft. lbs. (32 Nm).

    Click image to see an enlarged view
    Fig. Installing the 2 M8 bolts
  3. Tighten the 8 M12 bolts in the sequence shown in 2 stages.
    1. Stage 1: Tighten 90°.
    2. Stage 2: Tighten an additional 90°.
      NOTE
      The camshaft gear must turn freely on the camshaft. Do not tighten the bolt at this time.


      NOTE
      The right-hand camshaft sprocket bolt is a left-hand threaded bolt.



      Click image to see an enlarged view
      Fig. Identifying the M12 bolt tightening sequence (RH side)
  4. Remove the rubber band, position the camshaft sprocket and chain. Loosely install the bolt.
  5. Install the RH side cassette bolt. Tighten to 106 inch lbs. (12 Nm).
LH side

NOTE
To avoid damage to the timing chain cassette, an assistant will be required to help position the cylinder head in the vehicle.


NOTE
New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.

  1. Position the LH cylinder head. Install 8 new M12 bolts and tighten in the sequence shown in 2 stages.
    1. Stage 1: Tighten to 106 inch lbs. (12 Nm).
    2. Stage 2: Tighten to 18 ft. lbs. (25 Nm).

      Click image to see an enlarged view
      Fig. Identifying the M12 bolt tightening sequence (LH side)
  2. Install the 2 new M8 bolts and tighten to 24 ft. lbs. (32 Nm).
  3. Tighten the 8 M12 bolts in the same sequence as above in 2 stages.
    1. Stage 1: Tighten 90°.
    2. Stage 2: Tighten an additional 90°.
      NOTE
      The camshaft gear must turn freely on the camshaft. Do not tighten the bolt at this time.
  4. Remove the rubber band, position the camshaft sprocket and chain. Loosely install the bolt.
  5. Install the LH side cassette bolt. Tighten to 168 inch lbs. (19 Nm).
Both sides

NOTE
LH side shown, RH side similar.

  1. Install the 12 exhaust manifold studs. Tighten to 106 inch lbs. (12 Nm).
    NOTE
    LH side shown, RH side similar.
  2. Position new gaskets and the exhaust manifolds. Install the 12 new nuts. Tighten to 17 ft. lbs. (23 Nm).
    NOTE
    Apply dielectric compound to the inside of the spark plug wire boots.
  3. Connect the 6 spark plug wires to the spark plugs.
    NOTE
    LH side shown, RH side similar.
  4. Install the 4 new catalytic converter-to-exhaust manifold nuts.
    1. Tighten to 33 ft. lbs. (45 Nm).
      NOTE
      Lubricate the new O-ring seals with clean engine oil.
  5. Install the 6 fuel injectors. Install new O-ring seals on the injectors. Install the injectors.
  6. Position the fuel rail and injectors and install the 4 bolts. Tighten to 17 ft. lbs. (23 Nm).
    NOTE
    The LH and RH camshafts must be retimed when either camshaft is disturbed.
  7. Turn the crankshaft clockwise to position the No. 1 cylinder at Top Dead Center (TDC).
    NOTE
    Do not rotate the engine counterclockwise. Rotating the engine counterclockwise will result in damage to the damper crank sensor speed wheel and incorrect timing to the engine.


    NOTE
    The Crankshaft TDC Timing Tool must be installed on the damper and should contact the engine block, this positions the engine at TDC.
  8. Install the Crankshaft TDC Timing Tool.
    NOTE
    Leave the top 2 Camshaft Sprocket Holding Tool clamp bolts loose.
  9. Install the Camshaft Sprocket Holding Tool and Adapter on the rear of the RH cylinder head.
    NOTE
    The camshaft timing slots are off-center.
  10. Position the camshaft timing slots below the centerline of the camshaft to correctly fit the Camshaft Holding Tool and Adapter, and install the Camshaft Holding Tool and Adapters on the front of the RH cylinder head.
  11. Install the Timing Chain Tensioner.
  12. Tighten the 2 top Camshaft Sprocket Holding Tool bolts to 89 inch lbs. (10 Nm).
    NOTE
    The RH camshaft sprocket bolt is a LH-threaded bolt.
  13. Using the Torque Wrench Extension with the Camshaft Sprocket Nut Socket 303-565, tighten the camshaft bolt to 63 ft. lbs. (85 Nm).
  14. Install a new washer and the RH camshaft tensioner. Tighten to 32 ft. lbs. (44 Nm).
    NOTE
    Leave the top 2 Camshaft Sprocket Holding Tool clamp bolts loose.
  15. Install the Camshaft Sprocket Holding Tool and Adapter on the front of the LH cylinder head.
    NOTE
    The camshaft timing slots are off-center.
  16. Position the camshaft timing slots below the centerline of the camshaft to correctly fit the Adapters, and install the Camshaft Holding Tool and Adapter on the rear of the LH cylinder head.
  17. Install the Timing Chain Tensioner.
  18. Tighten the bolts.
    1. Tighten the Camshaft Sprocket Holding Tool top 2 bolts to 89 inch lbs. (10 Nm).
    2. Tighten the camshaft sprocket bolt to 63 ft. lbs. (85 Nm).
  19. Install a new washer and the LH camshaft tensioner. Tighten to 32 ft. lbs. (44 Nm).
LH side
  1. Position the ground strap and install the bolt. Tighten to 30 ft. lbs. (40 Nm). Attach the wiring harness retainer to the backside of the cylinder head.
  2. Position the starter motor wiring retainer bracket and install the bolt. Tighten to 30 ft. lbs. (40 Nm).
  3. Position the FEAD bracket and A/C compressor. Install the 3 bolts and the nut. Tighten to 35 ft. lbs. (48 Nm).
  4. Position the power steering pump and install the 3 bolts. Tighten to 18 ft. lbs. (25 Nm).
  5. Position the power steering pump pulley and install the 3 bolts. Tighten to 18 ft. lbs. (25 Nm).
  6. Attach the PSP tube bracket to the crossmember and install the bolt. Tighten to 97 inch lbs. (11 Nm).
  7. Attach the power steering supply hose bracket to the FEAD bracket and install the bolt. Tighten to 97 inch lbs. (11 Nm).
  8. Position the ground strap and install the stud bolt. Tighten to 89 inch lbs. (10 Nm).
  9. Install the oil level indicator tube and bolt. Tighten to 97 inch lbs. (11 Nm).
RH side

NOTE
Inspect the o-ring seal. Install a new o-ring seal if necessary.

  1. Position the thermostat housing and install the 3 bolts. Tighten to 97 inch lbs. (11 Nm).
  2. Position the coolant bypass hose clamp and connect the ECT sensor electrical connector.
  3. Install the upper radiator hose.
  4. Connect the heater hose to the thermostat housing.
  5. Position the generator mounting bracket assembly and install the 2 bolts and the nut. Tighten to 35 ft. lbs. (47 Nm).
  6. Install the accessory drive belt tensioner and bolt. Tighten to 35 ft. lbs. (47 Nm).
  7. Connect the generator electrical connector. Position the B+ terminal and install the nut. Tighten to 71 inch lbs. (8 Nm). Attach the pin type retainer.
  8. Install the 2 coolant tube bracket bolts. Tighten the M12 bolt to 25 ft. lbs. (34 Nm). Tighten the M8 bolt to 17 ft. lbs. (23 Nm).
Both sides
  1. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt.
  2. Install the hydraulic lash adjusters.
  3. Install the intake manifold.
  4. Fill and bleed the engine cooling system.
These details will help.
Thanks.
FOR MORE HELP GO TO: ---
Car repair guide?


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