Monday, March 12, 2012

How to replace Cylinder Head on Ford Windstar?

The details to replace Cylinder head on ford windstar are as follows :----


Cylinder Head
REMOVAL & INSTALLATION Instructions are mentioned below :---

3.0L Engine
  1. Rotate the crankshaft to 0 TDC on the compression stroke.
  2. Remove or disconnect the following:
    NOTE
    The fuel injectors and fuel injection supply manifold may be removed with the lower intake manifold as an assembly.



    Negative battery cable
    Coolant
    Cowl top vent panel
    Air cleaner outlet tube from the throttle body
    All necessary vacuum lines
    EGR backpressure transducer from the EGR valve
    EGR valve tube away from the valve
    All necessary engine wiring
    Fuel system pressure
    Fuel line safety clips and disconnect the fuel lines



    Ignition wires and ignition coil pack
    Upper radiator and heater hoses
    Camshaft position sensor
  3. If the front cylinder head is being removed, perform the following:
    1. Disconnect the alternator electrical harness.
    2. Rotate the tensioner clockwise and remove the accessory drive belt.
    3. Remove the automatic belt tensioner assembly.
    4. Remove the alternator.
    5. Remove the power steering mounting bracket retaining bolts. Leave the hoses connected and place the pump aside in a position to prevent fluid from leaking out.
    6. Remove the engine oil dipstick tube from the exhaust manifold.
  4. If the rear cylinder head is being removed, perform the following:
    1. Remove the alternator belt tensioner bracket.
    2. Remove the heater supply tube retaining brackets from the exhaust manifold.
    3. Remove the vehicle speed sensor cable retaining bolt.
    4. Remove the EGR vacuum regulator sensor and bracket.
  5. Remove or disconnect the following:
    NOTE
    Pushrods must be installed in their original positions. Note pushrod location during removal.



    Valve covers



    Pushrods
    Lower intake manifold
    Spark plugs
    Exhaust manifolds
    Cylinder head bolts
    Cylinder head from the engine block and discard the gaskets
To install:
  1. The cylinder head should be cleaned and inspected prior to installation.
  2. Lightly oil all bolt and stud bolt threads before installation.
  3. Clean all gasket mating surfaces thoroughly.
  4. Install or connect the following:
    WARNING
    Always use new cylinder head bolts when installing the cylinder head or damage to the engine may occur.


    NOTE
    When the cylinder head attaching bolts have been tightened using this procedure, it is not necessary to retighten the bolts after extended engine operation. The bolts can be rechecked for tightness if desired.


    NOTE
    The rocker arm seats must be fully seated in the cylinder head and the pushrods must be seated in the rocker arm sockets prior to the final tightening.



    New head gaskets on the cylinder block, noting the UP position mark on the gasket face and using the dowels in the engine block for alignment. If the dowels are damaged, they must be replaced.



    Cylinder head on the cylinder block. Tighten the cylinder head bolts in 2 steps following the proper torque sequence. The first step is 37 ft. lbs. (50 Nm) and the second step is 68 ft. lbs. (92 Nm).

    Click image to see an enlarged view
    Fig. Cylinder head bolt torque sequence-3.0L engine



    Intake manifold
    All engine wiring harnesses previously disconnected
    Pushrods. Dip each end in engine assembly lubricant.
    Rocker arms, seats and retaining bolts. Lubricate all rocker arm components with engine assembly lubricant. Tighten the bolts to 62-132 inch lbs. (7-15 Nm).



    Final tighten all rocker arm retaining bolts to 20-28 ft. lbs. (26-38 Nm)
    Exhaust manifolds
    Spark plugs
    Valve covers
  5. If the rear cylinder head is being installed, perform the following:
    1. Install the EGR vacuum regulator sensor and bracket.
    2. Install the vehicle speed sensor cable retaining bolt.
    3. Install the heater supply tube retaining brackets from the exhaust manifold.
    4. Install the alternator belt tensioner bracket.
    5. Install the engine oil dipstick tube from the exhaust manifold.
  6. If the front cylinder head is being installed, perform the following:
    1. Install the power steering mounting bracket retaining bolts. Leave the hoses connected and place the pump aside in a position to prevent fluid from leaking out.
    2. Install the alternator.
    3. Install the automatic belt tensioner assembly.
    4. Rotate the tensioner clockwise and install the accessory drive belt.
    5. Connect the alternator electrical harness.
  7. Install or connect the following:

    Camshaft position sensor
    Upper radiator and heater hoses
    Ignition coil pack and spark plug wires
    Fuel lines and fuel line safety clips
    EGR valve tube
    EGR backpressure transducer
    All necessary vacuum lines
    Air cleaner outlet tube to the throttle body
    Cowl top vent panel
  8. Fill and bleed the cooling system.
    NOTE
    Engine coolant is corrosive to engine bearing material. Replace the engine oil after removal of any coolant-carrying component to help prevent potential bearing damage.
  9. Change the engine oil and filter
  10. Connect the negative battery cable.
  11. Start the engine and check for leaks.
3.8L Engine
  1. Remove or disconnect the following:

    Negative battery cable
    Coolant
    Air cleaner assembly
    Cowl top vent panel
    Accessory drive belt
  2. If the front cylinder head is being removed, perform the following:
    1. Remove the oil filler cap.
    2. Remove the air conditioning compressor mounting bracket and set the air conditioning compressor aside with the refrigerant lines still connected.
    3. Remove the power steering pump and bracket. Leave the power steering hoses connected and place the pump aside in the engine compartment.
    4. Remove the alternator and mounting bracket.
  3. If the rear cylinder head is being removed, perform the following:
    1. Remove the accessory drive belt tensioner.
    2. Remove the PCV valve.
    3. Remove the power steering line bracket.
    4. Remove the tensioner bracket.
    5. Remove the coil pack assembly.
  4. Remove or disconnect the following:
    NOTE
    Pushrods must be installed in their original positions. Note pushrod location during removal.



    Upper intake manifold
    Valve cover
    Fuel system pressure
    Fuel charging assembly
    Lower intake manifold
    Exhaust manifolds



    Pushrods
    Cylinder head bolts
    Cylinder head from the engine block and discard the gaskets
To install:
  1. The cylinder head should be cleaned and inspected prior to installation.
  2. Lightly oil all bolt and stud bolt threads before installation.
  3. Clean all gasket mating surfaces thoroughly.
  4. Position new head gaskets on the cylinder block, noting the UP position mark on the gasket face, using the dowels in the engine block for alignment. If the dowels are damaged, they must be replaced. 
    WARNING
    Always use new cylinder head bolts when installing cylinder head or damage to the engine may occur.
  5. Position the cylinder head on the cylinder block.
  6. Lubricate the cylinder head bolts with engine oil and install. Tighten the cylinder head bolts following the proper torque sequence as follows:
    NOTE
    Do not loosen all of the cylinder head bolts at once. Only work on 1 bolt at a time or damage to the engine may occur.



    Step 1: 15 ft. lbs. (20 Nm)
    Step 2: 29 ft. lbs. (40 Nm)
    Step 3: 37 ft. lbs. (50 Nm)

    Click image to see an enlarged view
    Fig. Cylinder head bolt torque sequence-3.8L engine
In sequence, loosen each cylinder head bolt 2-3 turns and retighten in 2 steps.


Long bolts, step 1: 29-37 ft. lbs. (40-50 Nm); step 2: tighten an additional 175-185 degrees.
Short bolts, step 1: 15-22 ft. lbs. (20-30 Nm); second 2: tighten an additional 175-185 degrees.

  1. Dip each pushrod end in engine assembly lubricant. Install the pushrods in their original positions.
  2. Lubricate all rocker arm components with engine assembly lubricant.
  3. For the rocker arm being installed, rotate the engine clockwise until the valve tappet rests on the heel (base circle) of the camshaft lobe.
  4. Install the rocker arms, seats and bolts and tighten to 44 inch lbs. (5 Nm).
  5. Perform the previous 2 steps for each rocker arm.
  6. After all rocker arms have been installed, final tighten all bolts to 22-29 ft. lbs. (30-40 Nm).
  7. Install or connect the following:

    Exhaust manifolds
    Lower intake manifold
    Fuel injection charging assembly
    Valve covers with new gaskets. Tighten the bolts to 71-97 inch lbs. (8-11 Nm).
    Upper intake manifold
    Spark plugs and ignition wires
  8. If the front cylinder head is being installed, perform the following:
    1. Install the alternator and mounting bracket.
    2. Install the power steering pump and bracket.
    3. Install the air conditioning compressor bracket.
    4. Install the oil filler cap.
  9. If the rear cylinder head is being installed, perform the following:
    1. Install the coil pack assembly.
    2. Install the tensioner bracket.
    3. Install the power steering line bracket.
    4. Install the PCV valve.
    5. Install the accessory drive belt tensioner.
    6. Rotate the tensioner clockwise and install the accessory drive belt.
  10. Install the cowl top vent panel.
  11. Install the air cleaner assembly.
  12. Fill and bleed the cooling system.
  13. Connect the negative battery cable.


This will help.Thanks.




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