LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Ford >> 2000 >> Contour SVT >> Repair and Diagnosis >> External Pages >> Different car >> Section 1366 (Engine System) >> Removal >> Cylinder Head
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Cylinder Head

WARNING: This page is about a different car, the 2006 Mercury Grand Marquis and 2006 Ford Crown Victoria. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL(S) DESCRIPTION

G04583583
 Remover, Crankshaft Vibration Damper
303-009 (T58P-6316-D)
G04583584
 Remover, Crankshaft Front Oil Seal
303-107 (T74P-6700-A)
G04583585
 Engine Lifting Bracket Set
303-DS086 (D93P-6001-A)
G04583586
 Compressor, Valve Spring
303-567 (T97P-6565-AH)
G04583587
 Spacer, Valve Spring Compressor
303-382 (T91P-6565-AH)
G04583588
 Remover/Installer, Cylinder Head
303-572 (T97T-6000-A)
MATERIAL SPECIFICATIONS

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

    Cylinder heads 

    WARNING: If equipped with fire suppression system, depower the system. For important safety warnings and procedures, refer to FIRE SUPPRESSION SYSTEM .
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Remove the engine. For additional information, refer to ENGINE  in the Removal portion of this article.
  3. Remove the bolts and the flexplate.
    Fig 1: Locating Flexplate Bolts
    G03885612Courtesy of FORD MOTOR CO.
  4. Remove the engine/transmission spacer plate.
    Fig 2: Removing Engine/Transmission Spacer Plate
    G04583590Courtesy of FORD MOTOR CO.
  5. Mount the engine on a suitable engine stand.
    Fig 3: Mounting Engine On Suitable Engine Stand
    G04583591Courtesy of FORD MOTOR CO.
  6. Remove the LH and the RH lifting brackets.
    Fig 4: Removing LH And RH Lifting Brackets
    G04583592Courtesy of FORD MOTOR CO.
  7. Remove the bolts and the RH engine mount.
    Fig 5: Removing RH Engine Mount
    G04583593Courtesy of FORD MOTOR CO.
    8. NOTE: LH shown, RH similar.
  8. Remove the drain plugs from the engine block. Allow the coolant to completely drain.
    • Install the drain plugs when finished.
    • To install, tighten to 20 Nm (15 lb-ft).
      Fig 6: Removing Drain Plugs From Engine Block
      G04583594Courtesy of FORD MOTOR CO.
  9. Remove the bolt and the battery cables from the engine.
    Fig 7: Removing Bolt And Battery Cables From Engine
    G04583595Courtesy of FORD MOTOR CO.
  10. Disconnect the exhaust gas recirculation (EGR) tube from the exhaust manifold.
    Fig 8: Disconnecting Exhaust Gas Recirculation (EGR) Tube From Exhaust Manifold
    G04583596Courtesy of FORD MOTOR CO.
  11. Disconnect the 8 ignition coil electrical connectors.
    Fig 9: Disconnecting Eight Ignition Coil Electrical Connectors
    G04583597Courtesy of FORD MOTOR CO.
  12. Disconnect the 8 fuel injector electrical connectors.
    Fig 10: Disconnecting Eight Fuel Injector Electrical Connectors
    G04583598Courtesy of FORD MOTOR CO.
  13. Remove the bolts and the intake manifold shield.
    Fig 11: Removing Bolts And Intake Manifold Shield
    G04583599Courtesy of FORD MOTOR CO.
  14. Remove the crankcase ventilation tube.
    Fig 12: Removing Crankcase Ventilation Tube
    G04583600Courtesy of FORD MOTOR CO.
  15. Remove the generator mounting bracket.
    • Remove the bolts.
    • Remove the bracket.
      Fig 13: Removing Generator Mounting Bracket
      G04583601Courtesy of FORD MOTOR CO.
  16. Disconnect the throttle control and the throttle position (TP) sensor electrical connectors.
    Fig 14: Locating Throttle Control And Throttle Position (TP) Sensor Electrical Connectors
    G03881492Courtesy of FORD MOTOR CO.
  17. Disconnect the generator electrical connector.
    Fig 15: Disconnecting Generator Electrical Connector
    G04583603Courtesy of FORD MOTOR CO.
  18. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
    Fig 16: Disconnecting Cylinder Head Temperature (CHT) Sensor Electrical Connector
    G04583604Courtesy of FORD MOTOR CO.
  19. Remove the generator wiring harness anchor from the LH front stud.
    Fig 17: Removing Generator Wiring Harness Anchor From LH Front Stud
    G04583605Courtesy of FORD MOTOR CO.
  20. Disconnect the ground wire from the RH rear stud.
    Fig 18: Disconnecting Ground Wire From RH Rear Stud
    G04583606Courtesy of FORD MOTOR CO.
  21. Disconnect the camshaft position (CMP) sensor electrical connector.
    Fig 19: Disconnecting Camshaft Position (CMP) Sensor Electrical Connector
    G04583607Courtesy of FORD MOTOR CO.
  22. Disconnect the radio ignition interference capacitor and remove the engine control sensor wiring.
    Fig 20: Removing Engine Control Sensor Wiring
    G04583608Courtesy of FORD MOTOR CO.
  23. Disconnect the fuel charging wiring from the crash bracket and the wiring support bracket and remove the harness from the engine.
    Fig 21: Removing Harness From Engine Assembly
    G04583609Courtesy of FORD MOTOR CO.
  24. Disconnect the EGR tube nut from the EGR system module.
    Fig 22: Disconnecting EGR Tube Nut From EGR System Module
    G04583610Courtesy of FORD MOTOR CO.
  25. Remove the generator.
    1. Remove the bolts.
    2. Remove the generator.
      Fig 23: Removing Generator And Bolts
      G04583611Courtesy of FORD MOTOR CO.
  26. Remove the intake manifold crash bracket bolt and prevent the bolt from contacting the cylinder head with a rubber band or tie strap.
    Fig 24: Removing Crash Bracket Bolt
    G04583612Courtesy of FORD MOTOR CO.
  27. Remove the intake manifold crash bracket stud bolt.
    Fig 25: Removing Intake Manifold Crash Bracket Stud Bolt
    G04583613Courtesy of FORD MOTOR CO.
  28. Remove the 8 bolts and the 8 ignition coils.
    Fig 26: Removing Bolts And Ignition Coils
    G04583614Courtesy of FORD MOTOR CO.
  29. Remove the 2 bolts and the coolant outlet adapter.
    Fig 27: Removing Bolts And Coolant Outlet Adapter
    G04583615Courtesy of FORD MOTOR CO.
  30. Remove the thermostat.
    Fig 28: Removing Thermostat
    G04583616Courtesy of FORD MOTOR CO.
  31. Remove the bolts and the intake manifold.
    Fig 29: Removing Bolts And Intake Manifold
    G04583617Courtesy of FORD MOTOR CO.
  32. Remove the intake manifold gaskets and discard.
    Fig 30: Removing Intake Manifold Gaskets
    G04583618Courtesy of FORD MOTOR CO.
    33. 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.
    Fig 31: Cleaning Sealing Surfaces
    G04583619Courtesy of FORD MOTOR CO.
  33. Clean the sealing surfaces.
  34. Remove the coolant bypass tube.
    1. Remove the retaining nut.
    2. Remove the ground strap.
    3. Remove the coolant bypass tube.
      Fig 32: Removing Coolant Bypass Tube
      G04583620Courtesy of FORD MOTOR CO.
  35. Loosen the studs and bolts and remove the valve cover.
    • Clean the mating surface and discard gasket.
      Fig 33: Loosening Studs And Bolts
      G04583621Courtesy of FORD MOTOR CO.
  36. Loosen the studs and bolts and remove the right valve cover.
    • Clean the mating surface and discard the gasket.
      Fig 34: Cleaning Mating Surface
      G04583622Courtesy of FORD MOTOR CO.
    37. CAUTION: Only use hand tools when removing or installing the spark plugs, damage can occur to the cylinder head or spark plug.
    NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs.
    Fig 35: Removing Spark Plugs
    G04583623Courtesy of FORD MOTOR CO.
  37. Remove the spark plugs.
  38. Position the lobe of the camshaft up.
    Fig 36: Positioning Lobe Of Camshaft Up
    G04583624Courtesy of FORD MOTOR CO.
  39. Install the special tool between the valve spring coils to prevent valve stem seal damage.
    Fig 37: Installing Special Tool Between Valve Spring Coils
    G03962476Courtesy of FORD MOTOR CO.
    40. NOTE: The roller followers are positional. Mark the followers for installation in their original locations.
    Fig 38: Removing Camshaft Roller
    G04583626Courtesy of FORD MOTOR CO.
  40. Use the special tool to compress the valve springs and remove the camshaft roller followers.
  41. Remove the bolt and the belt idler pulley.
    Fig 39: Removing Belt Idler Pulley
    G04583627Courtesy of FORD MOTOR CO.
  42. Remove the coolant pump pulley.
    Fig 40: Removing Coolant Pump Pulley
    G04583628Courtesy of FORD MOTOR CO.
  43. Remove the crankshaft pulley bolt.
    Fig 41: Removing Crankshaft Pulley Bolt
    G04583629Courtesy of FORD MOTOR CO.
  44. Using the special tool, remove the crankshaft pulley.
    Fig 42: Removing Crankshaft Pulley
    G04583630Courtesy of FORD MOTOR CO.
  45. Using the special tool, remove the crankshaft front oil seal.
    Fig 43: Removing Crankshaft Front Seal Using Special Tool
    G03919889Courtesy of FORD MOTOR CO.
  46. Remove the front 4 oil pan bolts.
    Fig 44: Locating Front Oil Pan Bolts
    G03885291Courtesy of FORD MOTOR CO.
  47. Remove the fasteners.
    Fig 45: Identifying Front Cover Fasteners
    G03885685Courtesy of FORD MOTOR CO.
  48. Remove the engine front cover from the cylinder block.
    • Clean the sealing surfaces and discard the gaskets.
      Fig 46: Locating Engine Front Cover
      G03885740Courtesy of FORD MOTOR CO.
  49. Remove the crankshaft sensor ring.
    Fig 47: View Of Crankshaft Sensor Ring At Crankshaft
    G04583449Courtesy of FORD MOTOR CO.
  50. Position the crankshaft with the keyway at the 12 o'clock position.
    Fig 48: Positioning Crankshaft With Keyway At 12 O'clock Position
    G04583456Courtesy of FORD MOTOR CO.
  51. Remove the timing chain tensioning system from both timing chains.
    1. Remove the bolts.
    2. Remove the timing chain tensioners.
    3. Remove the timing chain tensioner arms.
      Fig 49: Identifying Timing Chain Tensioning System
      G03962450Courtesy of FORD MOTOR CO.
  52. Remove the LH and RH timing chains and the crankshaft sprocket.
    • Remove the RH timing chain from the camshaft sprocket.
    • Remove the RH timing chain from the crankshaft sprocket.
    • Repeat for the LH timing chain and crankshaft sprocket.
      Fig 50: View Of Left And Right Timing Chains, Sprockets And Crankshaft Gear
      G03885313Courtesy of FORD MOTOR CO.
  53. Remove both timing chain guides.
    1. Remove the bolts.
    2. Remove the LH timing chain guide.
    3. Remove the bolts.
    4. Remove the RH timing chain guide.
      Fig 51: Identifying Timing Chain Guides
      G03962452Courtesy of FORD MOTOR CO.

    54. RH cylinder head 

  54. Remove the RH exhaust manifold.
    1. Remove the nuts.
    2. Remove the RH exhaust manifold.
    3. Remove and discard the RH exhaust manifold gasket.
      Fig 52: Locating Exhaust Manifold
      G03947754Courtesy of FORD MOTOR CO.

    55. LH cylinder head 

  55. Remove the LH exhaust manifold.
    1. Remove the nuts.
    2. Remove the LH exhaust manifold.
    3. Remove and discard the LH exhaust manifold gaskets.
      Fig 53: Removing LH Exhaust Manifold
      G04583641Courtesy of FORD MOTOR CO.
  56. Remove the bolt and the oil level indicator tube.
    Fig 54: Removing Bolt And Oil Level Indicator Tube
    G04583642Courtesy of FORD MOTOR CO.

    57. Both cylinder heads 

  57. Clean and inspect the exhaust manifolds. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  58. Install the special tool on both ends of the cylinder head.
    Fig 55: Identifying Special Tool (303-572)
    G04671899Courtesy of FORD MOTOR CO.
    59. NOTE: The hydraulic lash adjusters must be reinstalled in their original locations. Record the hydraulic lash adjuster locations.
    Fig 56: Identifying Hydraulic Lash Adjusters
    G03885650Courtesy of FORD MOTOR CO.
  59. Remove the hydraulic lash adjusters.

    60. RH cylinder head 

    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: 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.
    CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
  60. Remove the bolts and the RH cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
      Fig 57: Locating Cylinder Head Bolts
      G03885651Courtesy of FORD MOTOR CO.

    61. LH cylinder head 

    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: 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.
    CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
  61. Remove the bolts and the LH cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
      Fig 58: Identifying LH Cylinder Head Bolts
      G03885652Courtesy of FORD MOTOR CO.

    62. Both cylinder heads 

    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 that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
    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.
  62. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head 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.
    63. NOTE: The straightedge used must be flat within 0.0051 mm (0.0002 in) per foot of tool length.
  63. Support the cylinder head 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 head 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).
scientia non olet · About LEMON Manuals