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Cylinder Head: Removal

CAUTION: 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 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 requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.
CAUTION: 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.

    All engines 

  1. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  2. Remove the battery tray. For additional information, refer to BATTERY MOUNTING AND CABLES .
  3. Drain the cooling system. For additional information, refer to ENGINE COOLING .
  4. Check the valve clearance. For additional information, refer to VALVE CLEARANCE CHECK  in this article.
  5. Remove the nuts and disconnect the catalytic converter from the exhaust assembly.
    • Remove and discard the gasket.
      Fig 1: Locating Catalytic Converter Nuts
      G04652051Courtesy of FORD MOTOR CO.
  6. Remove the 2 bolts and the catalytic converter support bracket from the engine.
    Fig 2: Locating Catalytic Converter Support Bracket And Bolts
    G04652052Courtesy of FORD MOTOR CO.
    7. NOTE: All 2.3L engines and some 2.0L engines are equipped with a heat shield that must be positioned aside to access the catalytic converter-to-engine nuts.
    Fig 3: Locating Heat Shield Bolts
    G04652053Courtesy of FORD MOTOR CO.
  7. If equipped, remove the 4 heat shield bolts and position the heat shield aside.
  8. Disconnect the exhaust sensor electrical connectors.
    Fig 4: Locating Exhaust Sensor Electrical Connectors
    G04652054Courtesy of FORD MOTOR CO.
  9. Remove and discard the catalytic converter-to-engine nuts.
    • Position aside the catalytic converter and support with mechanic's wire.
    • Remove and discard the catalytic converter gasket.
      Fig 5: Locating Catalytic Converter-To-Engine Nuts
      G04652055Courtesy of FORD MOTOR CO.
  10. Remove the generator. For additional information, refer to GENERATOR AND REGULATOR .
  11. Remove the fuel injection supply manifold. For additional information, refer to FUEL CHARGING AND CONTROLS - 2.0L AND 2.3L .
  12. Remove the intake manifold. For additional information, refer to INTAKE MANIFOLD  in this article.
  13. Remove the timing drive components. For additional information, refer to TIMING DRIVE COMPONENTS  in this article.
  14. Remove the special tool.
    Fig 6: Identifying Special Camshaft Tool (303-465)
    G03898006Courtesy of FORD MOTOR CO.
  15. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.
    Fig 7: Locating Camshaft Lobe
    G03898791Courtesy of FORD MOTOR CO.
    16. CAUTION: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.
  16. Remove the camshafts from the engine.
    • Loosen the camshaft bearing cap bolts, in sequence, one turn at a time.
    • Repeat the first step until all tension is released from the camshaft bearing caps.
    • Remove the camshaft bearing caps.
    • Remove the camshafts.
      Fig 8: Identifying Loosening/Tightening Sequence Of Camshaft Bearing Bolts
      G03897808Courtesy of FORD MOTOR CO.
    17. CAUTION: If the camshafts and valve tappets are to be reused, mark the location of the valve tappets to make sure they are assembled in their original positions.
  17. Remove the valve tappets.
    18. NOTE: The number on the valve tappets only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm.
  18. Inspect the valve tappets. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .

    19. 2.0L engines 

  19. If equipped, disconnect the secondary air injection (AIR) vacuum regulator electrical connector and vacuum hose.
    Fig 9: Locating Secondary Air Injection Vacuum Regulator Electrical Connector And Vacuum Hose
    G04652059Courtesy of FORD MOTOR CO.
  20. If equipped, disconnect the hoses from the AIR control valve.
    Fig 10: Locating AIR control valve And Hoses
    G04652060Courtesy of FORD MOTOR CO.
  21. If equipped, disconnect the upper exhaust sensor electrical connector and retainer.
    Fig 11: Locating Upper Exhaust Sensor Electrical Connector And Retainer
    G04652061Courtesy of FORD MOTOR CO.

    22. All engines 

  22. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
  23. Disconnect the coolant hoses from the coolant bypass.
  24. Remove the 4 bolts, coolant bypass and gasket.
    • Discard the gasket.
  25. Disconnect the EGR coolant hose.
  26. Remove the bolts and the cylinder head.
    • Discard the bolts.
  27. Remove and discard the head gasket.
  28. Inspect the cylinder head mating surfaces. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
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