Sunday, March 11, 2012

Ford Taurus 2000 to 2005 Cylinder Head Removal?

The procedure to replace Cylinder Head Is as follows :----


Cylinder Head
REMOVAL & INSTALLATION  details are mentioned below:---
3.0L (VIN S) Engine
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2. Remove the engine from the vehicle and mount it on an engine stand.
Remove or disconnect the following:
NOTE
The crankshaft accessory drive pulley shaft has left-hand threads. Rotate the pulley shaft clockwise to remove.


NOTE
Keep the lash adjusters in order for installation.



Upper intake manifold
Lower intake manifold

  • Exhaust manifolds

    Valve covers

    Radiator hose tube and bracket

    Accessory drive belt

    Crankcase ventilation tube

    Heater hose bypass tube

    Power steering pump

    A/C compressor and bracket

    Water pump



Crankshaft pulley
Oil pan
Front cover
Timing chains
Camshafts
Valve lash adjusters
  1. Remove the cylinder head bolts from the cylinder heads in sequence and remove the cylinder heads.

    Click image to see an enlarged view
    Fig. Cylinder head bolt removal sequence-right side head shown, left side similar-3.0L (VIN S) engine


    Click image to see an enlarged view
    Fig. Right side valve cover bolt removal sequence-3.0L (VIN S) engine


    Click image to see an enlarged view
    Fig. Left side valve cover bolt removal sequence-3.0L (VIN S) engine
To install:

NOTE
The cylinder head bolts are a torque-to-yield design and cannot be reused.


NOTE
Left and right cylinder head gaskets are not interchangeable.



Click image to see an enlarged view
Fig. Cylinder head torque sequence-3.0L (VIN S) engine
  1. Install new gaskets and install the cylinder heads. Use new bolts and tighten as follows:
    1. Step 1: Tighten the bolts in sequence to 28-31 ft. lbs. (37-43 Nm).
    2. Step 2: Plus 85-95 degrees.
    3. Step 3: Loosen the bolts in reverse sequence 1 full turn.
    4. Step 4: Tighten the bolts in sequence to 28-31 ft. lbs. (37-43 Nm).
    5. Step 5: Tighten the bolts in sequence 85-95 degrees.
    6. Step 6: Tighten the bolts in sequence 85-95 degrees.
  2. Install or connect the following:

    Valve lash adjusters in their original locations
    Camshafts
    Timing chains
    Front cover
    Oil pan
    Crankshaft pulley
    Water pump
    A/C compressor and bracket
    Power steering pump
    Heater hose bypass tube
    Crankcase ventilation tube
    Accessory drive belt
    Radiator hose tube and bracket
    Valve covers
    Exhaust manifolds
    Lower intake manifold
    Upper intake manifold
    Engine assembly into the vehicle.
  3. Run the engine and check for leaks.

    Click image to see an enlarged view
    Fig. Left side valve cover bolt tightening sequence-3.0L (VIN S) engine


    Click image to see an enlarged view
    Fig. Right side valve cover bolt tightening sequence-3.0L (VIN S) engine
Left Side
  1. Before servicing the vehicle, refer to the precautions section.
  2. Release the fuel system pressure.
  3. Drain and recycle the engine coolant.
  4. Remove the water pump bypass tube.
  5. Remove the exhaust manifold-to-pipe nuts.
  6. Remove the water pump.
  7. Remove the lower intake manifold.
  8. Remove the camshafts.
  9. Install and engine support tool and lower the engine until it is aligned with the A/C compressor bracket, and finger-tighten the four bolts.
  10. Remove the engine support tool.
  11. Remove the camshaft followers.
  12. Remove the hydraulic lash adjusters.
  13. Remove the nuts and remove the exhaust manifold and discard the gasket.
  14. Remove the dipstick tube.
  15. Inspect and, if necessary, install a new O-ring seal.
  16. Remove the left hand cylinder block drain plug.
    NOTE
    New cylinder head bolts must be installed. They are torque-to-yield designed and cannot be reused.
  17. Remove the bolts in the sequence shown and remove the cylinder head.
  18. Discard the gasket and the bolts.
To install:
  1. Position the cylinder head, gasket and install the bolts in the sequence shown in six steps:
    1. Step 1: Tighten to 30 ft. lbs. (40 Nm).
    2. Step 2: Tighten bolts 90 degrees.
    3. Step 3: Loosen one full turn.
    4. Step 4: Tighten to 30 ft. lbs. (40 Nm).
    5. Step 5: Tighten 90 degrees.
    6. Step 6: Tighten 90 degrees.
  2. Install the cylinder block drain plug and tighten to 49 ft. lbs. (67 Nm).
    NOTE
    Lubricate the oil dipstick tube O-ring with clean engine oil.
  3. Install the oil dipstick tube and the nut.
  4. Position a new gasket and install the exhaust manifold nuts.
  5. Install the hydraulic lash adjusters. Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.
  6. Install the camshaft followers. Lubricate the camshaft followers with clean engine oil prior to installation
  7. Install the engine support tool.
  8. Remove the four A/C compressor bracket bolts.
  9. Using the engine support tool, raise the engine away from the A/C compressor bracket.
  10. Install the camshafts.
  11. Install the lower intake manifold.
  12. Install the water pump.
  13. Install the exhaust manifold-to-pipe nuts.
  14. Install the water pump bypass tube.
  15. Run the engine and check for leaks.
Right Side
  1. Before servicing the vehicle, refer to the precautions section.
  2. Remove the engine from the vehicle and mount it on an engine stand.
  3. Remove or disconnect the following:
    NOTE
    The crankshaft accessory drive pulley shaft has left-hand threads. Rotate the pulley shaft clockwise to remove.


    NOTE
    Keep the lash adjusters in order for installation.



    Upper intake manifold
    Lower intake manifold
    Exhaust manifolds
    Valve covers
    Radiator hose tube and bracket
    Accessory drive belt
    Crankcase ventilation tube
    Heater hose bypass tube
    Power steering pump
    A/C compressor and bracket
    Water pump



    Crankshaft pulley
    Oil pan
    Front cover
    Timing chains
    Camshafts
    Valve lash adjusters
  4. Remove the cylinder head bolts from the cylinder heads in sequence and remove the cylinder heads.

    Click image to see an enlarged view
    Fig. Cylinder head bolt removal sequence-right side head shown, left side similar-3.0L (VIN S) engine


    Click image to see an enlarged view
    Fig. Right side valve cover bolt removal sequence-3.0L (VIN S) engine


    Click image to see an enlarged view
    Fig. Left side valve cover bolt removal sequence-3.0L (VIN S) engine
To install:

NOTE
The cylinder head bolts are a torque-to-yield design and cannot be reused.


NOTE
Left and right cylinder head gaskets are not interchangeable.



Click image to see an enlarged view
Fig. Cylinder head torque sequence-3.0L (VIN S) engine
  1. Install new gaskets and install the cylinder heads. Use new bolts and tighten as follows:
    1. Step 1: Tighten the bolts in sequence to 28-31 ft. lbs. (37-43 Nm).
    2. Step 2: Plus 85-95 degrees.
    3. Step 3: Loosen the bolts in reverse sequence 1 full turn.
    4. Step 4: Tighten the bolts in sequence to 28-31 ft. lbs. (37-43 Nm).
    5. Step 5: Tighten the bolts in sequence 85-95 degrees.
    6. Step 6: Tighten the bolts in sequence 85-95 degrees.
  2. Install or connect the following:

    Valve lash adjusters in their original locations
    Camshafts
    Timing chains
    Front cover
    Oil pan
    Crankshaft pulley
    Water pump
    A/C compressor and bracket
    Power steering pump
    Heater hose bypass tube
    Crankcase ventilation tube
    Accessory drive belt
    Radiator hose tube and bracket
    Valve covers
    Exhaust manifolds
    Lower intake manifold
    Upper intake manifold
    Engine assembly into the vehicle.
  3. Run the engine and check for leaks.

    Click image to see an enlarged view
    Fig. Left side valve cover bolt tightening sequence-3.0L (VIN S) engine


    Click image to see an enlarged view
    Fig. Right side valve cover bolt tightening sequence-3.0L (VIN S) engine
  1. Before servicing the vehicle, refer to the precautions section.
  2. Release the fuel system pressure.
  3. Remove the water pump bypass tube.
  4. Remove the rear support brace.
  5. Remove the lower intake manifold.
  6. Remove the camshafts.
  7. Install and engine support tool and lower the engine until it is aligned with the A/C compressor bracket, and finger-tighten the four bolts.
  8. Remove the engine support tool.
  9. Remove the exhaust manifold-to-pipe bolts.
  10. Disconnect the Exhaust Gas Recirculation (EGR) tube from the exhaust manifold.
  11. Remove the bolt and the ground wire.
  12. Remove the camshaft followers.
  13. Remove the hydraulic lash adjusters.
  14. Remove the nuts and remove the exhaust manifold and discard the gasket.
  15. Remove the right hand cylinder block drain plug.
    NOTE
    New cylinder head bolts must be installed. They are torque-to-yield designed and cannot be reused.
  16. Remove the bolts in the sequence shown and remove the cylinder head.
  17. Discard the gasket and the bolts.
To install:
  1. Position the cylinder head, gasket and install the bolts in the sequence shown in six steps: Tighten the bolts in six Steps.
    1. Step 1: Tighten to 30 ft. lbs. (40 Nm).
    2. Step 2: Tighten bolts 90 degrees.
    3. Step 3: Loosen one full turn.
    4. Step 4: Tighten to 30 ft. lbs. (40 Nm).
    5. Step 5: Tighten 90 degrees.
    6. Step 6: Tighten 90 degrees.
  2. Install the cylinder block drain plug and tighten to 49 ft. lbs. (67 Nm).
  3. Position a new gasket and install the exhaust manifold nuts.
  4. Install the hydraulic lash adjusters. Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.
  5. Install the camshaft followers. Lubricate the camshaft followers with clean engine oil prior to installation
  6. Install the ground wire and bolt.
  7. Connect the EGR tube to the exhaust manifold. Tighten to 30 ft. lbs. (40 Nm).
  8. Install the exhaust manifold-to-pipe bolts. Tighten to 30 ft. lbs. (40 Nm).
  9. Install the engine support tool.
  10. Remove the four A/C compressor bracket bolts.
  11. Using the engine support tool, raise the engine away from the A/C compressor bracket.
  12. Install the camshafts.
  13. Install the lower intake manifold.
  14. Install the rear support brace. Tighten to 35 ft. lbs. (47 Nm).
  15. Install the water pump bypass tube.
  16. Run the engine and check for leaks.
3.0L (VIN U) Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2. Drain the cooling system.
  3. Set the No. 1 cylinder to Top Dead Center (TDC) of the compression stroke.
  4. Remove or disconnect the following:

    Negative battery cable
    Air cleaner outlet hose
    Vacuum hoses from the intake manifold
    Exhaust Gas Recirculation (EGR) valve
    EGR transducer
    EGR vacuum regulator solenoid
    Intake Air Temperature (IAT) sensor connector
    Throttle Position (TP) sensor connector
    Intake Air Control (IAC) valve connector
    Camshaft Position (CMP) sensor and housing
    Engine Coolant Temperature (ECT) sensor connector
    Accelerator cable
    Cruise control cable
    Fuel lines
    Upper intake manifold
    Fuel injector wiring harness
    Coolant hoses
    Ignition coil and bracket
    Spark plug wires
    Accessory drive belt and tensioner
    Alternator
    Power steering pump
    Oil dipstick tube
    Heater supply tube brackets
    Valve covers
    Rocker arms and pushrods. Keep the rocker arms and pushrods in order for installation.
    Lower intake manifold
    Spark plugs
    Exhaust manifolds
    Cylinder heads
To install:

NOTE
The cylinder head bolts are a torque-to-yield design and cannot be reused.



Click image to see an enlarged view
Fig. Install the cylinder head gasket with the -UP- designation on gasket facing the cylinder head-2001-04 3.0L (VIN U) engines


Click image to see an enlarged view
Fig. Cylinder head torque sequence-2001-04 3.0L (VIN U) engine
  1. Install the cylinder heads with new gaskets.
  2. Tighten the bolts in sequence as follows:
    1. Step 1: 36-39 ft. lbs. (47-53 Nm).
    2. Step 2: Loosen the bolts 1 complete turn.
    3. Step 3: Tighten the bolts to 20-24 ft. lbs. (27-33 Nm).
    4. Step 4: Tighten the bolts 85-95 degrees.
    5. Step 5: Tighten the bolts 85-95 degrees.
  3. Install or connect the following:

    Exhaust manifolds
    Spark plugs
    Lower intake manifold
    Rocker arms and pushrods in their original locations. Tighten the rocker arm bolts to 24 ft. lbs. (32 Nm). Tighten each rocker arm bolt with the valve closed and the lifter on the camshaft lobe base circle. Rotate the crankshaft as necessary.
    Valve covers

    Click image to see an enlarged view
    Fig. Valve cover tightening sequence-2001-04 3.0L (VIN U) engine
    Heater supply tube brackets
    Oil dipstick tube and tighten the nut to 13 ft. lbs. (18 Nm)
    Power steering pump
    Alternator
    Accessory drive belt and tensioner
    Spark plug wires
    Ignition coil and bracket. Tighten the fasteners to 30-39 ft. lbs. (40-55 Nm).
    Coolant hoses
    Fuel injector wiring harness
    Upper intake manifold
    Fuel lines
    Cruise control cable
    Accelerator cable
    ECT sensor connector
    CMP sensor and housing
    IAC valve connector
    TP sensor connector
    IAT sensor connector
    EGR vacuum regulator solenoid
    EGR transducer
    EGR valve
    Vacuum hoses from the intake manifold
    Air cleaner outlet hose
    Negative battery cable
  4. Fill the cooling system and check for leaks.
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2. Drain the cooling system.
  3. Set the No. 1 cylinder to Top Dead Center (TDC) of the compression stroke.
  4. Remove or disconnect the following:

    Negative battery cable
    Air cleaner outlet hose
    Vacuum hoses from the intake manifold
    Exhaust Gas Recirculation (EGR) valve
    EGR transducer
    EGR vacuum regulator solenoid
    Intake Air Temperature (IAT) sensor connector
    Throttle Position (TP) sensor connector
    Intake Air Control (IAC) valve connector
    Camshaft Position (CMP) sensor and housing
    Engine Coolant Temperature (ECT) sensor connector
    Accelerator cable
    Cruise control cable
    Fuel lines
    Upper intake manifold
    Fuel injector wiring harness
    Coolant hoses
    Ignition coil and bracket
    Spark plug wires
    Accessory drive belt and tensioner
    Alternator
    Power steering pump
    Oil dipstick tube
    Heater supply tube brackets
    Valve covers
    Rocker arms and pushrods. Keep the rocker arms and pushrods in order for installation.
    Lower intake manifold
    Spark plugs
    Exhaust manifolds
    Cylinder heads
To install:

NOTE
The cylinder head bolts are a torque-to-yield design and cannot be reused.
Click image to see an enlarged view
Fig. Cylinder head torque sequence-3.0L (VIN U) engine
  1. Install the cylinder heads with new gaskets.
  2. On 1998 models, tighten the bolts in sequence as follows:
    1. Step 1: 53-66 ft. lbs. (70-90 Nm).
    2. Step 2: Loosen the bolts 1 complete turn.
    3. Step 3: Tighten the bolts to 34-40 ft. lbs. (45-55 Nm).
    4. Step 4: Tighten the bolts to 63-73 ft. lbs. (85-99 Nm).
  3. On 1999-02 models, tighten the bolts in sequence as follows:
    1. Step 1: 36-39 ft. lbs. (47-53 Nm).
    2. Step 2: Loosen the bolts 1 complete turn.
    3. Step 3: Tighten the bolts to 20-24 ft. lbs. (27-33 Nm).
    4. Step 4: Tighten the bolts 85-95 degrees.
    5. Step 5: Tighten the bolts 85-95 degrees.
  4. Install or connect the following:

    Exhaust manifolds
    Spark plugs
    Lower intake manifold
    Rocker arms and pushrods in their original locations. Tighten the rocker arm bolts to 24 ft. lbs. (32 Nm). Tighten each rocker arm bolt with the valve closed and the lifter on the camshaft lobe base circle. Rotate the crankshaft as necessary.
    Valve covers
    Heater supply tube brackets
    Oil dipstick tube and tighten the nut to 13 ft. lbs. (18 Nm)
    Power steering pump
    Alternator
    Accessory drive belt and tensioner
    Spark plug wires
    Ignition coil and bracket. Tighten the fasteners to 30-39 ft. lbs. (40-55 Nm).
    Coolant hoses
    Fuel injector wiring harness
    Upper intake manifold
    Fuel lines
    Cruise control cable
    Accelerator cable
    ECT sensor connector
    CMP sensor and housing
    IAC valve connector
    TP sensor connector
    IAT sensor connector
    EGR vacuum regulator solenoid
    EGR transducer
    EGR valve
    Vacuum hoses from the intake manifold
    Air cleaner outlet hose
    Negative battery cable
  5. Fill the cooling system and check for leaks.

    Click image to see an enlarged view
    Fig. Valve cover tightening sequence-3.0L (VIN U) engine
Left Side
  1. Before servicing the vehicle, refer to the precautions section.
  2. Remove the lower intake manifold.
  3. Remove the accessory drive belt.
  4. Remove the retainers and the engine anti-roll strut brace.
  5. Disconnect the alternator electrical connections.
  6. Remove the retainers and the alternator.
  7. Remove the bolt and the drive belt idler pulley.
  8. Remove the bolt and the drive belt tensioner pulley.
  9. Remove the spark plug wires.
  10. Remove the exhaust manifold.
  11. Remove the power steering pump and bracket assembly as follows:.
    1. Disconnect the power steering return hose.
    2. Remove the bolt.
    3. Remove the two nuts.
  12. Remove the eight cylinder head bolts.
  13. Remove the cylinder heads.
  14. Remove and discard the head gasket.
To install:
  1. Using metal surface cleaner, clean the cylinder head sealing surfaces.
    NOTE
    The "V" notch in the cylinder head gasket faces the front of the engine.
  2. Install a new cylinder head gasket.
  3. Install the cylinder head.
  4. Install the bolts. Tighten the bolts in five steps in the sequence shown.
    1. Step 1: Tighten to 37 ft. lbs. (50 Nm).
    2. Step 2: Loosen the bolts one full turn.
    3. Step 3: Tighten to 22 ft. lbs (30 Nm).
    4. Step 4: Rotate each bolt 90 degrees.
    5. Step 5: Rotate each bolt an additional 90 degrees. Install the bolts. Tighten the bolts in five stages in the sequence shown. Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Loosen the bolts one full turn. Stage 3: Tighten to 30 Nm (22 lb-ft). Stage 4: Rotate an additional 90 degrees. Stage 5: Rotate an additional 90 degrees.
  5. Install the power steering pump and bracket assembly as follows:
    1. Install the bolt and the two nuts. Tighten to 35 ft. lbs. (48 Nm).
    2. Connect the power steering return hose.
  6. Install the exhaust manifold.
  7. Install the spark plug wires.
  8. Install the drive belt tensioner and bolt. Tighten to 35 ft. lbs. (48 Nm).
  9. Install the drive belt idler pulley and bolt. Tighten to 35 ft. lbs. (48 Nm).
  10. Install the alternator and the retainers.
  11. Connect the alternator electrical connections.
  12. Install the engine anti-roll strut brace and the retainers. Tighten to 35 ft. lbs. (48 Nm).
  13. Install the accessory drive belt.
  14. Install the lower intake manifold.
Right Side
  1. Before servicing the vehicle, refer to the precautions section.
  2. Remove the lower intake manifold.
  3. Disconnect the Crankshaft Position (CKP) sensor connector.
  4. Disconnect the Heated Oxygen (HO 2 S) sensor connector.
  5. Remove the nut and disconnect the wiring harness ground connections.
  6. Loosen the bolt and disconnect the Powertrain Control Module (PCM) electrical connector.
  7. Disconnect the Evaporative Emissions (EVAP) canister purge valve electrical connector.
  8. Disconnect the spark plug wires and position the wires aside.
  9. Loosen the nut and disconnect the Exhaust Gas Recirculation (EGR) tube.
  10. Remove the three bolts and the exhaust manifold heat shield.
  11. Loosen the exhaust manifold-to-catalytic converter bolts.
  12. Remove the six exhaust manifold-to-cylinder head bolts.
  13. Disconnect the engine wire harness locator.
  14. Remove the bolt and separate the catalytic converter heat shield from the cylinder head.
  15. Remove the eight cylinder head bolts.
  16. Remove the cylinder head.
  17. Remove and discard the head gasket.
To install:
  1. Using metal surface cleaner, clean the cylinder head sealing surfaces.
    NOTE
    The "V" notch in the cylinder head gasket faces the front of the engine.
  2. Install a new cylinder head gasket.
  3. Install the cylinder head.
  4. Install the bolts. Tighten the bolts in five steps in the sequence shown.
    1. Step 1: Tighten to 37 ft. lbs. (50 Nm).
    2. Step 2: Loosen the bolts one full turn.
    3. Step 3: Tighten to 22 ft. lbs (30 Nm).
    4. Step 4: Rotate each bolt 90 degrees.
    5. Step 5: Rotate each bolt an additional 90 degrees.

      Click image to see an enlarged view
      Fig. Cylinder head torque sequence, right side show, left side similar-2005 3.0L (VIN U) models
  5. Install the catalytic converter heat shield and wire harness ground connection.
  6. Position the wiring harness and install the harness locator.
  7. Install the exhaust manifold.
  8. Tighten the exhaust manifold-to-catalytic converter bolts to 30 ft. lbs. (40 Nm).
  9. Install the exhaust manifold heat shield.
  10. Install the EGR tube and tighten to 37 ft. lbs. (50 Nm).
  11. Connect the spark plug wires.
  12. Connect the EVAP canister purge valve electrical connector.
  13. Connect the PCM electrical connector.
  14. Connect the wire harness ground connections.
  15. Connect the HO 2 S sensor electrical connector.
  16. Connect the CKP electrical connector.
  17. Install the lower intake manifold.


  1. Install new gaskets and install the cylinder heads. Use new bolts and tighten in sequence as follows:
    1. Step 1: 20-23 ft. lbs. (27-32 Nm).
    2. Step 2: Plus 85-95 degrees.
  2. Install or connect the following:

    Camshafts
    Timing chain
    CKP pulse ring
    Front cover
    Accessory belt idler pulleys
    Oil pan
    CKP sensor
    CMP sensor
    Crankshaft pulley
    Power steering pump
    Spark plugs
    Left and right valve covers
    Water pump
    Water crossover pipe
    Lower intake manifold
    IMRC cable and bracket
    Exhaust manifolds
    Secondary air injection valve, tubes, and brackets
    Engine control sensor wiring harness and brackets
    Left and right intake manifolds
    Surge tank and supports
    Throttle body
    EGR tube
    Intake vacuum lines
    Oil dipstick tube
    Water pump drive pulley
    Alternator
    A/C compressor
    Accessory drive belts
    Engine assembly into the vehicle.
  3. Run the engine and check for leaks.


This details will help you.

Thanks.


FOR MORE HELP GO TO: ---

Car repair guide?

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


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