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Home › Lincoln › 2006 › LS › Repair and Diagnosis › Engine Mechanical › Mechanical › Engine › Removal › Cylinder Heads

Cylinder Heads

SPECIAL TOOL(S)

G04690400Courtesy of FORD MOTOR CO.
 Strap Wrench
303-D055
G04690401Courtesy of FORD MOTOR CO.
 Remover, Crankshaft Vibration Damper
303-009 (T58P-6316-D)
G04690402Courtesy of FORD MOTOR CO.
 Remover, Oil Seal
303-409 (T92C-6700-CH)
G04690403Courtesy of FORD MOTOR CO.
 Alignment Gauge, Crankshaft
303-645
G04690404Courtesy of FORD MOTOR CO.
 Aligner, Camshaft
303-530
MATERIAL SPECIFICATION

Item Specification
Silicone Gasket Remover ZC-30 -
Motorcraft Metal Surface Prep ZC-31 -

    Both sides 

  1. Remove the engine. For additional information, refer to ENGINE .
  2. Install the engine on a suitable engine stand.
  3. Remove the engine block plug to drain the engine coolant.
  4. Disconnect the oil pressure and oil temperature sensor electrical connectors.
    Fig 1: Locating Oil Pressure And Oil Temperature Sensor Electrical Connectors
    G04690405Courtesy of FORD MOTOR CO.
  5. Remove and discard the oil filter.
    Fig 2: Locating Oil Filter
    G04690406Courtesy of FORD MOTOR CO.
    6. CAUTION: A new oil cooler must be installed or severe damage to the engine can occur.
  6. Remove the bolt and oil cooler.
    • Discard the oil cooler and gasket.
  7. Remove the bolt and the accessory drive belt tensioner.
    Fig 3: Locating Accessory Drive Belt Tensioner And Bolt
    G04690407Courtesy of FORD MOTOR CO.
  8. Remove the bolt and the accessory drive belt idler pulley.
    Fig 4: Locating Accessory Drive Belt Idler Pulley And Bolt
    G04690408Courtesy of FORD MOTOR CO.
  9. Remove the 3 bolts and the coolant pump pulley.
    Fig 5: Locating Coolant Pump Pulley And Bolts
    G04690409Courtesy of FORD MOTOR CO.
    10. NOTE: Hold the crankshaft pulley with the special tool while removing the bolt and washer.
    Fig 6: Identifying Special Tool
    G04690410Courtesy of FORD MOTOR CO.
  10. Remove and discard the bolt and washer.
  11. Using the special tool, remove the crankshaft damper.
    Fig 7: Identifying Special Tool
    G04690411Courtesy of FORD MOTOR CO.
  12. Using the special tool, remove and discard the front crankshaft seal.
    Fig 8: Identifying Special Tool
    G04690412Courtesy of FORD MOTOR CO.
    13. NOTE: LH shown, RH similar.
  13. Remove the LH and RH ignition coil covers.
  14. Remove all silicone sealer and residue from the ignition coil covers.
    Fig 9: Locating Ignition Coil Covers Silicone Sealer Applying Area
    G04690413Courtesy of FORD MOTOR CO.
    15. NOTE: LH shown, RH similar.
    Fig 10: Locating Silicone Sealer And Residue
    G04690414Courtesy of FORD MOTOR CO.
  15. Remove all silicone sealer and residue from the valve cover surface and ignition coil wiring harness.
  16. Disconnect the 8 ignition coil electrical connectors.
    Fig 11: Locating Ignition Coil Electrical Connectors
    G04690415Courtesy of FORD MOTOR CO.
  17. Disconnect the throttle position (TP) sensor electrical connector.
    Fig 12: Locating Throttle Position (TP) Sensor Electrical Connector
    G04690416Courtesy of FORD MOTOR CO.
  18. Disconnect the fuel pressure sensor electrical connector.
    Fig 13: Locating Fuel Pressure Sensor Electrical Connector
    G04690417Courtesy of FORD MOTOR CO.
  19. Disconnect the electronic throttle body electrical connector.
    Fig 14: Locating Electronic Throttle Body Electrical Connector
    G04690418Courtesy of FORD MOTOR CO.
  20. Disconnect the evaporative emissions (EVAP) tube.
    Fig 15: Locating Evaporative Emissions (EVAP) Tube
    G04690419Courtesy of FORD MOTOR CO.
  21. Disconnect the fuel rail temperature sensor electrical connector.
    Fig 16: Locating Fuel Rail Temperature Sensor Electrical Connector
    G04690420Courtesy of FORD MOTOR CO.
  22. Disconnect the exhaust gas recirculation (EGR) system module electrical connector.
    Fig 17: Locating EGR System Module Electrical Connector
    G04690421Courtesy of FORD MOTOR CO.
  23. Disconnect the coolant vent hose from the coolant outlet.
    • Remove the coolant vent hose.
      Fig 18: Locating Coolant Vent Hose
      G04690422Courtesy of FORD MOTOR CO.
  24. Remove the vacuum harness.
    Fig 19: Locating Vacuum Harness
    G04690423Courtesy of FORD MOTOR CO.
    25. NOTE: LH shown, RH similar.
    Fig 20: Locating Engine Wiring Harness
    G04690424Courtesy of FORD MOTOR CO.
  25. Disconnect the engine wiring harness retainers from the engine appearance cover support brackets.
  26. Detach the vacuum hose retainers from the LH engine appearance cover support bracket.
    Fig 21: Locating Vacuum Hose Retainers
    G04690425Courtesy of FORD MOTOR CO.
    27. NOTE: RH shown, LH similar.
    Fig 22: Locating Engine Appearance Cover Brackets And Nuts
    G04690426Courtesy of FORD MOTOR CO.
  27. Remove the 4 nuts and the 2 engine appearance cover brackets.
    28. NOTE: LH shown, RH similar.
    Fig 23: Locating Fuel Injector And Radio Interference Capacitor Electrical Connectors
    G04690427Courtesy of FORD MOTOR CO.
  28. Disconnect the 8 fuel injector and the 2 radio interference capacitor electrical connectors.
  29. Disconnect the knock sensor (KS) and camshaft position (CMP) senor electrical connectors.
    • Detach the pin-type retainers.
      Fig 24: Locating KS And CMP Sensor Electrical Connectors
      G04690428Courtesy of FORD MOTOR CO.
    30. NOTE: RH shown, LH similar.
    Fig 25: Locating VCT Sensor Electrical Connectors
    G04690429Courtesy of FORD MOTOR CO.
  30. Disconnect the 2 variable cam timing (VCT) sensor electrical connectors.
  31. Remove the 5 bolts and the power steering bracket.
    Fig 26: Locating Power Steering Bracket Bolts And Bracket
    G04690430Courtesy of FORD MOTOR CO.
  32. Disconnect the wiring harness retainers from the LH valve cover.
    Fig 27: Locating Wiring Harness Retainers From LH Valve Cover
    G04690431Courtesy of FORD MOTOR CO.
  33. Detach the wiring harness from the engine front cover.
    Fig 28: Locating Wiring Harness From Engine Front Cover
    G04690432Courtesy of FORD MOTOR CO.
  34. Disconnect the crankshaft position (CKP) sensor electrical connector and wiring harness retainers.
    Fig 29: Locating Crankshaft Position (CKP) Sensor Electrical Connector And Wiring Harness Retainers
    G04690433Courtesy of FORD MOTOR CO.
  35. Disconnect the wiring harness retainers from the RH valve cover.
    Fig 30: Locating Wiring Harness Retainers At RH Valve Cover
    G04690434Courtesy of FORD MOTOR CO.
  36. Disconnect the generator electrical connector and wiring harness retainers.
    Fig 31: Locating Generator Electrical Connector, Wiring Harness And Retainers
    G04690435Courtesy of FORD MOTOR CO.
  37. Remove the heated oxygen sensor (HO2S) electrical connectors from the brackets.
    Fig 32: Locating Heated Oxygen Sensor (HO2S) Electrical Connector Brackets Bolts
    G04690436Courtesy of FORD MOTOR CO.
  38. Remove the engine wiring harness from the engine.
  39. Remove the nut and the oil level indicator tube.
    • Discard the O-ring seal.
      Fig 33: Locating Oil Level Indicator Tube And Nut
      G04690437Courtesy of FORD MOTOR CO.
  40. Remove the 8 bolts and the 8 ignition coils.
    Fig 34: Locating Ignition Coils And Bolts
    G04690438Courtesy of FORD MOTOR CO.
  41. Remove the crankcase vent tube.
    Fig 35: Locating Crankcase Vent Tube
    G04690439Courtesy of FORD MOTOR CO.
  42. Disconnect the exhaust manifold tube at the EGR system module.
    Fig 36: Locating Exhaust Manifold Tube At EGR System Module
    G04690440Courtesy of FORD MOTOR CO.
    43. NOTE: RH shown, LH similar.
    Fig 37: Locating Radio Interference Ignition Capacitors Mounting Bracket And Nuts
    G04690441Courtesy of FORD MOTOR CO.
  43. Remove the 2 nuts and the radio interference capacitors.
  44. Disconnect the throttle body heater hoses.
    Fig 38: Locating Throttle Body Coolant Hoses
    G04690442Courtesy of FORD MOTOR CO.
  45. Remove the 4 bolts and the coolant bypass housing.
    • Discard the O-ring seals.
      Fig 39: Locating Coolant Bypass Housing And Bolts
      G04690443Courtesy of FORD MOTOR CO.
  46. Remove the 4 bolts and the throttle body adapter.
    • Discard the gasket.
      Fig 40: Locating Throttle Body Adapter, Bolts And Gasket
      G04690444Courtesy of FORD MOTOR CO.
  47. Remove the 7 bolts and 3 studs in the sequence shown.
    • Remove the intake manifold.
    • Discard the gaskets.
      Fig 41: Identifying Intake Manifold Bolts And Studs Loosening Sequence
      G04690445Courtesy of FORD MOTOR CO.
    48. CAUTION: 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. Use a plastic scraping tool to clean the surfaces.
    Fig 42: Locating Sealing Surfaces
    G04690446Courtesy of FORD MOTOR CO.
  48. Clean the sealing surfaces.
  49. Remove the bolts in the sequence shown and remove the RH valve cover.
    • Discard the gasket.
      Fig 43: Identifying RH Valve Cover Bolt Removing Sequence
      G04690447Courtesy of FORD MOTOR CO.
  50. Remove the bolts in the sequence shown and remove the LH valve cover.
    Fig 44: Identifying LH Valve Cover Bolt Removing Sequence
    G04690448Courtesy of FORD MOTOR CO.
    51. CAUTION: 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. Use a plastic scraping tool to clean the surfaces.
    Fig 45: Locating Gaskets And Silicone Sealer
    G04690449Courtesy of FORD MOTOR CO.
  51. Remove the gaskets and all silicone sealer. Clean the mating surfaces with silicone gasket remover.

    52. RH side 

  52. Remove the 2 nuts and the EGR tube.
    • Discard the gasket.
      Fig 46: Locating Nuts And EGR Tube
      G04690450Courtesy of FORD MOTOR CO.
  53. Remove the 4 bolts and the RH exhaust manifold heat shield.
    Fig 47: Locating RH Exhaust Manifold Heat Shield And Bolts
    G04690451Courtesy of FORD MOTOR CO.
  54. Remove the nuts and the RH exhaust manifold.
    • Discard the nuts.
      Fig 48: Removing RH Exhaust Manifold And Nuts
      G04690452Courtesy of FORD MOTOR CO.
  55. Remove the RH exhaust manifold heat shield stud bolt.
    • Discard the exhaust manifold gasket.
      Fig 49: Locating RH Exhaust Manifold Heat Shield Stud Bolt
      G04690453Courtesy of FORD MOTOR CO.
  56. Remove the 8 RH exhaust manifold studs and discard.
  57. Clean and inspect the RH exhaust manifold. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .

    58. LH side 

  58. Remove the 4 bolts and the LH exhaust manifold heat shield.
    Fig 50: Locating LH Exhaust Manifold Heat Shield And Bolts
    G04690454Courtesy of FORD MOTOR CO.
  59. Remove the nuts and the LH exhaust manifold.
    • Discard the nuts.
      Fig 51: Locating LH Exhaust Manifold And Nuts
      G04690455Courtesy of FORD MOTOR CO.
  60. Remove the LH exhaust manifold heat shield stud bolt.
    • Discard the exhaust manifold gasket.
      Fig 52: Locating LH Exhaust Manifold Heat Shield Stud Bolt
      G04690456Courtesy of FORD MOTOR CO.
  61. Remove the 8 LH exhaust manifold studs and discard.
  62. Clean the inspect the LH exhaust manifold. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .

    63. Both sides 

  63. Remove the engine front cover bolts in the sequence shown.
    • Remove the engine front cover.
    • Discard the gaskets.
      Fig 53: Identifying Engine Front Cover Bolts Removing Sequence
      G04690457Courtesy of FORD MOTOR CO.
    64. CAUTION: 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. Use a plastic scraping tool to remove all traces of sealant.
    Fig 54: Locating Sealing Surfaces
    G04690458Courtesy of FORD MOTOR CO.
  64. Clean the sealing surfaces.
  65. Remove the RH and LH variable cam timing (VCT) bush carriers.
    Fig 55: Locating RH And LH Variable Cam Timing (VCT) Bush Carriers - Nut And Bolts
    G04690459Courtesy of FORD MOTOR CO.
  66. Remove the bolt and the CKP sensor.
    Fig 56: Locating Bolt And CKP Sensor
    G04690460Courtesy of FORD MOTOR CO.
    67. NOTE: There is one window on the ignition pulse wheel that is unique to accept the special tool.
  67. Install the special tool.
    • Turn the crankshaft to 45 degrees ATDC. The crankshaft keyway will be in the 6 o'clock position.
    • Install the special tool.
      Fig 57: Identifying Special Tool
      G04690461Courtesy of FORD MOTOR CO.
  68. Make sure the flats of the camshaft are facing upward. If not, repeat the previous step.
    Fig 58: Locating Camshaft Flats
    G04690462Courtesy of FORD MOTOR CO.
    69. CAUTION: The flats on the camshaft must completely contact the special service tool or damage to the camshafts can occur. Slowly draw the special tool down evenly until it is fully seated on the camshaft flats.
    Fig 59: Identifying Special Tool On RH Cylinder Head
    G04690463Courtesy of FORD MOTOR CO.
  69. Install the special tool on the RH cylinder head.
    70. CAUTION: An open-end wrench must be used on the hex area of the camshaft or damage to the head will occur.
    Fig 60: Locating Exhaust Camshaft Sprocket Bolt
    G04690464Courtesy of FORD MOTOR CO.
  70. Remove and discard the exhaust camshaft sprocket bolt.
    71. NOTE: An open-end wrench must be used on the hex area of the camshaft or damage to the head will occur.
    Fig 61: Locating VCT Unit Bolt
    G04690465Courtesy of FORD MOTOR CO.
  71. Remove and discard the VCT unit bolt.
  72. Remove the RH timing chain tensioner.
    1. Push the lever down and install a drill rod to lock the piston.
    2. Remove the 2 bolts and the tensioner.
      Fig 62: Identifying RH Timing Chain Tensioner And Bolt
      G04690466Courtesy of FORD MOTOR CO.
  73. Remove the bolt and the RH tensioner arm.
    Fig 63: Locating RH Timing Chain Tensioner Arm
    G04690467Courtesy of FORD MOTOR CO.
  74. Remove the bolt and the RH timing chain guide.
    Fig 64: Locating RH Timing Chain Guide And Bolt
    G04690468Courtesy of FORD MOTOR CO.
  75. Remove the RH primary timing chain.
    Fig 65: Locating RH Primary Timing Chain
    G04690469Courtesy of FORD MOTOR CO.
  76. Remove the special tool from the RH cylinder head.
    Fig 66: Identifying Special Tool On RH Cylinder Head
    G04690470Courtesy of FORD MOTOR CO.
    77. CAUTION: The flats on the camshaft must completely contact the special service tool or damage to the camshafts can occur. Slowly draw the special tool down evenly until it is fully seated on the camshaft flats.
    Fig 67: Identifying Special Tool
    G04690471Courtesy of FORD MOTOR CO.
  77. Install the special tool on the LH cylinder head.
    78. CAUTION: An open-end wrench must be used on the hex area of the camshaft or damage to the cylinder head will occur.
    Fig 68: Locating LH VCT Unit Bolt And Exhaust Camshaft Sprocket Bolt
    G04690472Courtesy of FORD MOTOR CO.
  78. Remove and discard the LH VCT unit bolt and the exhaust camshaft sprocket bolt.
  79. Remove the LH timing chain tensioner.
    1. Push the lever down and install a drill rod to lock the piston.
    2. Remove the 2 bolts and the tensioner.
      Fig 69: Identifying Timing Chain Tensioner Bolts And Drill Rod
      G04690473Courtesy of FORD MOTOR CO.
  80. Remove the nut and the LH tensioner arm.
    Fig 70: Locating LH Tensioner Arm And Nut
    G04690474Courtesy of FORD MOTOR CO.
  81. Remove the bolt and the LH timing chain guide.
    Fig 71: Locating LH Timing Chain Guide And Bolt
    G04690475Courtesy of FORD MOTOR CO.
  82. Remove the LH primary timing chain.
    Fig 72: Locating LH Timing Chain
    G04690476Courtesy of FORD MOTOR CO.
  83. Remove the crankshaft sprocket.
  84. Collapse the LH secondary timing chain tensioner and install a pin to lock the piston.
    Fig 73: Locating Locking Pin For LH Secondary Timing Chain Tensioner
    G04690477Courtesy of FORD MOTOR CO.
  85. Remove the LH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.
    Fig 74: Identifying LH VCT Unit, Exhaust Camshaft Sprocket And Timing Chain
    G04690478Courtesy of FORD MOTOR CO.
  86. Remove the 2 bolts and the LH secondary timing chain tensioner.
  87. Collapse the RH secondary timing chain tensioner and install a pin to lock the piston.
    Fig 75: Locating Locking Pin For RH Secondary Timing Chain Tensioner
    G04690479Courtesy of FORD MOTOR CO.
  88. Remove the RH VCT unit, exhaust camshaft sprocket and timing chain as an assembly.
    Fig 76: Locating RH VCT Unit, Exhaust Camshaft Sprocket And Timing Chain
    G04690480Courtesy of FORD MOTOR CO.
  89. Remove the 2 bolts and the RH secondary timing chain tensioner.
  90. Remove the special tool.
    Fig 77: Identifying Special Tool
    G04690481Courtesy of FORD MOTOR CO.

    91. LH side 

    CAUTION: Record the camshaft bearing cap locations. The camshaft bearing caps are positional and must be installed in their original locations and orientation or engine damage can occur.
  91. Remove the LH camshaft bearing caps.
    • Remove the bolts.
    • Remove the LH camshaft bearing caps.
      Fig 78: Locating LH Camshaft Bearing Caps
      G04690482Courtesy of FORD MOTOR CO.
  92. Remove the LH camshafts.
    Fig 79: Locating LH Camshafts
    G04690483Courtesy of FORD MOTOR CO.
    93. CAUTION: Do not use any means of marking the shims other than a permanent-type marker. Any scratches or paint on the shims can result in incorrect lash adjustments and severe engine damage.
    CAUTION: Record the shim and bucket tappet location. The shim and bucket tappet are positional and if installed in the incorrect location, engine damage can occur.
  93. Record the location of the valve tappets.
    • Remove the valve tappets.
    94. CAUTION: The cylinder head must be cool before removing it from the engine. Cylinder head warpage can result if a warm or hot cylinder head is removed.
    CAUTION: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.
    CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.
    CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
  94. Remove the LH cylinder head end bolts.
    • Discard the bolts.
      Fig 80: Locating LH Cylinder Head End Bolts
      G04690484Courtesy of FORD MOTOR CO.
  95. Remove and discard the bolts from LH cylinder head in the sequence shown.
    • Remove the cylinder head.
    • Discard the gasket.
      Fig 81: Identifying Cylinder Heads Bolts Removing Sequence
      G04690485Courtesy of FORD MOTOR CO.

    96. RH side 

    CAUTION: Record the camshaft bearing cap locations. The camshaft bearing caps are positional and must be installed in their original locations and orientation or engine damage can occur.
  96. Remove the RH camshaft bearing caps.
    • Remove the bolts.
    • Remove the RH camshaft bearing caps.
      Fig 82: Locating RH Camshafts Bearing Caps
      G04690486Courtesy of FORD MOTOR CO.
  97. Remove the RH camshafts.
    Fig 83: Locating RH Camshaft Bearing Caps
    G04690487Courtesy of FORD MOTOR CO.
    98. CAUTION: Do not use any means of marking the shims other than a permanent-type marker. Any scratches or paint on the shims can result in incorrect lash adjustments and severe engine damage.
    CAUTION: Record the shim and bucket tappet location. The shim and bucket tappet are positional and if installed in the incorrect location, engine damage can occur.
  98. Record the location of the valve tappets.
    • Remove the valve tappets.
    99. CAUTION: The cylinder head must be cool before removing it from the engine. Cylinder head warpage can result if a warm or hot cylinder head is removed.
    CAUTION: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.
    CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.
    CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
  99. Remove the RH cylinder head end bolts.
    • Discard the bolts.
      Fig 84: Locating RH Cylinder Head End Bolts
      G04690488Courtesy of FORD MOTOR CO.
  100. Remove and discard the bolts from the RH cylinder head in the sequence shown.
    • Remove the cylinder head.
    • Discard the gasket.
      Fig 85: Identifying Cylinder Heads Bolts Removing Sequence
      G04690489Courtesy of FORD MOTOR CO.

    101. Both sides 

    CAUTION: 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. Use a plastic scraping tool to remove all traces of sealant.
    CAUTION: 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.
  101. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder heads and the cylinder block.
    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.
    102. NOTE: The straightedge used must be flat within 0.0051 mm (0.0002 in) per foot of tool length.
  102. Support the cylinder heads on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge, paying particular attention to the oil pressure feed area. The cylinder heads must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area, or scratches more than 0.0254 mm (0.001 in).
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