Friday, March 16, 2012

How To Replace Cylinder Head On Ford Ranger?

The Details to replace Cylinder Head is as follows: ------


Cylinder Head
REMOVAL & INSTALLATION Procedure is as follows:---

2.3L Engine
Specific to:
Ford Ranger 2008-2009

WARNING
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 you loosen the pulley bolt. Before any repair required loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special tools, otherwise severe engine damage can occur.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Relieve the fuel pressure.
  3. Disconnect the negative battery cable.
  4. Drain the cooling system.
  5. Disconnect the battery ground cable.
  6. Remove the camshafts.
  7. Remove the exhaust manifold.
  8. Remove the fuel rail.
  9. Remove the coolant hose retainer clip, the stud bolt and the ground cable.
  10. Remove the EGR tube from the cylinder head.
  11. Disconnect the EGR valve electrical connector.
  12. Disconnect the EGR coolant hose and remove it from the hose bracket.
  13. Disconnect the coolant bypass hose.
  14. Remove the cylinder block coolant drain plug.
  15. Remove the 10 bolts and the cylinder head. Discard the bolts.
  16. Remove and discard the head gasket.
    WARNING
    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.
  17. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block in the following sequence:

    Remove any large deposits of silicone or gasket material with a plastic scraper.
    Apply silicone gasket remover, following package directions, and allow to set for several minutes.
    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.
    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.
  18. 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. Apply silicone gasket and sealant to the locations shown. 

image
Fig. Apply silicone gasket and sealant to the locations shown
  1. Install a new cylinder head gasket.
    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. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.


    WARNING
    The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.
  2. Lubricate the cylinder head bolts with clean engine oil.
  3. Install the cylinder head and the 10 new bolts.
  4. Tighten the bolts in the sequence shown, in 5 stages as follows: 

    Stage 1: Tighten to 44 inch lbs. (5 Nm).
    Stage 2: Tighten to 133 inch lbs. (15 Nm).
    Stage 3: Tighten to 33 ft. lbs. (45 Nm).
    Stage 4: Tighten an additional 90 degrees.
    Stage 5: Tighten another additional 90 degrees. 

    image
    Fig. Cylinder head tightening sequence
  5. Install the cylinder block coolant drain plug and tighten to 41 ft. lbs. (55 Nm).
  6. Connect the coolant bypass hose.
  7. Connect the EGR coolant hose.
  8. Connect the EGR valve electrical connector.
  9. Connect the EGR tube to the cylinder head and tighten to 41 ft. lbs. (55 Nm).
  10. Position the ground strap and install the stud bolt to the cylinder head. Tighten to 89 inch lbs. (10 Nm).
  11. Install the coolant hose retainer clip.
  12. Install the fuel rail.
  13. Install the exhaust manifold.
  14. Install the camshafts.
  15. Connect the battery ground cable.
  16. Drain the engine oil and install a new oil filter.
  17. Refill and bleed the cooling system.
3.0L Engine
Specific to:
Ford Ranger 2008
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. With the vehicle in NEUTRAL, position it on a hoist.
  3. Disconnect the battery ground cable.
  4. Relieve the fuel pressure.
  5. Drain the cooling system.
  6. Evacuate the A/C system.
  7. Position the air cleaner outlet tube aside.
  8. Remove the upper and lower intake manifold.
  9. Remove the drive belt from the A/C compressor pulley.
  10. Disconnect the electrical connector.
  11. Remove the clamp nut on the compressor manifold and tube assembly.
  12. Loosen the bolt and disconnect the compressor manifold and tube assembly from the A/C compressor.
  13. Remove the bolts and the A/C compressor. Discard the O-ring seals.
  14. Remove the alternator.
  15. Remove the power steering pump pulley.
  16. Disconnect the power steering pressure hose. Remove and discard the seal.
  17. Disconnect the power steering return hose.
  18. Disconnect the power steering return line hose.
  19. Remove the bolts and the power steering pump.
  20. Remove the alternator mounting bracket.
  21. Remove the rocker arms and the push rods.
  22. Remove the nuts and detach the fuel tube bracket and the wiring harness bracket.
  23. Remove the 2 stud bolts from the side of the A/C compressor and power steering pump bracket.
  24. Remove the bolt and the accessory drive belt tensioner.
  25. Remove the bolts and the A/C compressor and power steering pump bracket.
  26. Remove the exhaust manifolds.
  27. Remove the RH cylinder block coolant drain plug.
  28. Remove and discard the eight cylinder head bolts.
  29. Remove the cylinder heads.
  30. Remove and discard the cylinder head gaskets.
To install:
  1. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block in the following sequence:

    Remove any large deposits of silicone or gasket material with a plastic scraper.
    Apply silicone gasket remover, following package directions, and allow to set for several minutes.
    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.
    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.
  2. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion.
    NOTE
    The "V" notch in the head gasket faces the front of the engine.
  3. Install new cylinder head gaskets.
  4. Install the cylinder heads.
  5. Install the bolts. Tighten the bolts in five steps in the sequence shown.

    Step 1: Tighten to 37 ft. lbs. (50 Nm).
    Step 2: Loosen the bolts one full turn.
    Step 3: Tighten to 22 ft. lbs. (30 Nm).
    Step 4: Tighten the bolts 90 degrees.
    Step 5: Tighten the bolts an additional 90 degrees.

    Click image to see an enlarged view
    Fig. Cylinder head tightening sequence-3.0L engine
  6. Install the RH cylinder block coolant drain plug and tighten to 18 ft. lbs. (24 Nm).
  7. Install the exhaust manifolds.
  8. Install the A/C compressor and power steering pump bracket and the bolts. Tighten the bolts to 35 ft. lbs. (47 Nm).
  9. Install the accessory drive belt tensioner and the bolt. Tighten the bolt to 20 ft. lbs. (27 Nm).
  10. Install the A/C compressor and power steering pump bracket stud bolts. Tighten the stud bolts to 35 ft. lbs. (47 Nm).
  11. Position the wiring harness bracket and install the nut. Tighten to 89 inch lbs. (10 Nm).
    NOTE
    Do not tighten the rocker arm bolts at this time.
  12. Install the rocker arms, the fulcrums and the bolts.
  13. Install the generator bracket and the bolts. Tighten to 35 ft. lbs. (47 Nm).
  14. Install the power steering pump.
  15. Install the generator.
  16. Install the A/C compressor.
  17. Install the lower intake manifold.
  18. Install the push rods and tighten the rocker arm bolts to 24 ft. lbs. (34 Nm).
  19. Install the upper intake manifold.
  20. Drain the engine oil and replace the oil filter.
  21. Connect the negative battery cable.
  22. Fill the engine with clean engine oil.
  23. Fill and bleed the cooling system.
  24. Fill the power steering system.
  25. Vacuum and charge the A/C system.
  26. Start the engine and check for leaks, repair as needed.
4.0L Engine
Specific to:
Ford Ranger 2008-2009
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Relieve the fuel pressure.
  3. With the vehicle in NEUTRAL, position it on a hoist.
  4. Drain the engine cooling system.
  5. Remove the intake manifold.
  6. Remove the cooling fan shroud.
  7. Remove the roller followers.
  8. Rotate the accessory drive belt tensioner counterclockwise and remove the drive belt
  9. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector.
    NOTE
    The coolant bypass hose will be removed with the thermostat housing.
  10. Move the coolant bypass hose clamp off the coolant pump outlet.
  11. Remove the 3 bolts and the thermostat housing and coolant bypass hose.
  12. Remove the 4 bolts and the fuel rail and fuel injector assembly.
  13. If equipped, remove the nut and position the A/C hose bracket aside.
    WARNING
    Do not rotate the engine counterclockwise. Rotating the engine counterclockwise will result in damage to the damper crankshaft sensor speed wheel and incorrect timing of 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 Top Dead Center (TDC).
  14. Install the Crankshaft TDC Timing Tool.
  15. Disconnect the generator electrical connections.
  16. Remove the bolt and the accessory drive belt tensioner.
  17. Remove the 3 bolts and the generator bracket assembly.
  18. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
  19. Detach the 2 wiring harness retainers and position the wiring harness aside. Remove and discard the 2 retainers.
  20. Remove the 5 pushpins and the RH inner fender splash shield.
  21. Remove the RH hydraulic timing chain tensioner.
  22. Remove the RH exhaust manifold.
  23. Remove the bolt and position the wiring harness bracket aside.
  24. Install the camshaft sprocket holding tool and the adapter for 303-564.
    NOTE
    The RH camshaft sprocket is a LH-threaded bolt. Turning the bolt in the wrong direction can damage the bolt.



    Click image to see an enlarged view
    Fig. Install the camshaft sprocket holding tool and the adapter for 303-564
  25. Using the torque wrench extension and the camshaft sprocket nut socket, remove the RH camshaft bolt.

    Click image to see an enlarged view
    Fig. Install the camshaft sprocket nut socket 303-575 and loosen the camshaft sprocket bolt
  26. Remove the RH timing drive cassette upper bolt.
    NOTE
    Remove the camshaft sprocket from the timing chain to gain clearance to remove the cylinder head.
  27. 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.
  28. Remove the RH camshaft sprocket from the timing chain. Install a rubber band around the cassette and the timing chain.
  29. Remove the 4 bolts and position the power steering and A/C compressor bracket aside.
  30. Remove the bolt and detach the wiring harness from the LH cylinder head.
  31. Remove the bolt and the oil level indicator tube.
    NOTE
    Spark plug wires must be connected to the correct spark plug. Mark the spark plug locations before removing them.
  32. Using the spark plug wire remover, disconnect the LH spark plug wires from the LH spark plugs and remove the ignition coil.
  33. Remove the LH exhaust manifold.
  34. Remove the bolt and detach the ground strap.
  35. Remove the LH side hydraulic timing chain tensioner.
  36. Install the camshaft sprocket holding tool and the adapter for 303-564.
  37. Remove the LH camshaft sprocket bolt.
  38. Remove the LH timing drive cassette upper bolt.
  39. Remove the camshaft sprocket from the timing chain to gain clearance to remove the cylinder head.
  40. 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.
  41. Remove the LH camshaft sprocket from the timing chain. Install a rubber band around the cassette and the timing chain.
    NOTE
    To avoid damage to the timing chain cassette, an assistant will be required to help lift the cylinder head from the vehicle.
  42. Remove the 10 cylinder head bolts in the sequence shown. Discard all bolts.
  43. Remove the cylinder heads.

    Click image to see an enlarged view
    Fig. Cylinder head removal sequence-4.0L engine
  44. Remove and discard the head gasket.
    WARNING
    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.
  45. Clean the cylinder head gasket surfaces with metal surface cleaner.
  46. 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 gasket on the block.
    NOTE
    New cylinder head bolts must be installed. They are a torque-to-yield design and cannot be reused.
  3. Install the RH cylinder head. Install 8 new 12-mm bolts and tighten in the sequence shown in 2 stages:

    Stage 1: Tighten to 106 inch lbs. (12 Nm).
    Stage 2: Tighten to 18 ft. lbs. (25 Nm).
  4. Install 2 new 8-mm bolts and tighten to 24 ft. lbs. (32 Nm).
  5. Tighten the eight 12-mm bolts in the sequence shown in 2 stages:
    NOTE
    The camshaft gear must turn freely on the camshaft. DO NOT tighten the bolt at this time.



    Stage 1: Tighten 90 degrees.
    Stage 2: Tighten an additional 90 degrees.

    Click image to see an enlarged view
    Fig. Cylinder head tightening sequence-4.0L engine
  6. Remove the rubber band. Install the camshaft sprocket and bolt.
  7. Install the RH timing drive cassette upper bolt and tighten to 89 inch lbs. (10 Nm).
  8. Position the wiring harness bracket and install the bolt. Tighten to 21 ft. lbs. (28 Nm).
  9. Install the RH exhaust manifold.
  10. Install the RH inner fender splash shield and the 5 pushpins.
  11. Install 2 new wiring harness retainers and attach the wiring harness.
  12. Connect the CKP sensor electrical connector.
  13. Position the generator bracket and install the 3 bolts. Tighten to 31 ft. lbs. (42 Nm).
  14. Position the accessory drive belt tensioner and install the bolt.
  15. Install the LH cylinder head. Install 8 new 12-mm bolts and tighten in the sequence shown in 2 stages:

    Stage 1: Tighten to 106 inch lbs. (12 Nm).
    Stage 2: Tighten to 18 ft. lbs. (25 Nm).
  16. Install 2 new 8-mm bolts and tighten to 24 ft. lbs. (32 Nm).
  17. Tighten the eight 12-mm bolts in the sequence shown in 2 stages:
    NOTE
    The camshaft gear must turn freely on the camshaft. DO NOT tighten the bolt at this time.



    Stage 1: Tighten 90 degrees.
    Stage 2: Tighten an additional 90 degrees.
  18. Remove the rubber band. Install the camshaft sprocket and bolt.
  19. Install the LH timing drive cassette upper bolt and tighten to 89 inch lbs. (10 Nm).
  20. Position the ground strap and install the bolt. Tighten the bolt to 18 ft. lbs. (25 Nm).
  21. Install the LH exhaust manifold.
  22. Apply silicone brake caliper grease and dielectric compound to the inside of the spark plug boots.
  23. Position the ignition coil in the engine compartment and connect the spark plug wires to the LH spark plugs.
  24. Install the oil level indicator tube and bolt. Tighten to 89 inch lbs. (10 Nm).
  25. Attach the wiring harness to the LH cylinder head and install the bolt. Tighten to 89 inch lbs. (10 Nm).
  26. Position the power steering and A/C compressor bracket and install the 4 bolts. Tighten to 31 ft lbs. (42 Nm).
  27. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt.
    WARNING
    The LH and RH camshafts must be retimed when either camshaft is disturbed. Refer to the Camshaft Timing in the Camshaft and Valve Lifters section.


    NOTE
    Install the hydraulic chain tensioners during camshaft timing.
  28. Time the camshafts.
  29. Position the thermostat housing, making sure the bypass hose is connected to the coolant pump, and install the 3 bolts. Tighten to 97 inch lbs. (11 Nm).
  30. Position the bypass hose clamp.
  31. Connect the ECT sensor electrical connector.
  32. Position the fuel rail and fuel injector assembly and install the 4 bolts. Tighten to 17 ft. lbs. (23 Nm).
  33. Connect the spring lock coupling.
  34. Install the roller followers.
  35. Install the cooling fan shroud.
  36. Install the intake manifold.
  37. Change the engine oil and filter.
  38. Refill and bleed the cooling system.
    WARNING
    The LH and RH camshafts must be retimed when either camshaft is disturbed. Refer to the Camshaft Timing in the Camshaft and Valve Lifters section.
  39. Start the engine and check for leaks, repair if necessary.

These details will help.
Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

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



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