Thursday, March 15, 2012

How To Replace Cylinder Head on Ford Expedition and Lincoln Navigator?


The procedure is similar for both ford and Lincoln car models:-----

The details to remove Cylinder head are as follows:----

Removal & Installation

CAUTION
Fuel injection systems remain under pressure, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.


NOTE
To correctly tighten the cylinder head bolts, an angle torque wrench is needed.

  1. Before servicing the vehicle, refer to the precautions section.
  2. Remove the engine.
  3. Remove the bolts and the flexplate.
  4. Install the engine onto a suitable engine stand.
  5. Disconnect the right hand Camshaft Position (CMP) sensor connector.
  6. Remove the stud bolt and the right hand radio ignition interference capacitor.
  7. Disconnect the right hand Variable Camshaft Timing (VCT) solenoid connector.
  8. Disconnect the 2 engine wiring harness retainers from the right hand valve cover studs.
  9. Disconnect the connector retainer from the coolant tube.
  10. Disconnect the 4 right hand ignition coil connectors.
  11. Disconnect the Cylinder Head Temperature (CHT) sensor connector.
  12. Disconnect the 2 engine wiring harness retainers from the left hand valve cover studs.
  13. Disconnect the left hand VCT solenoid connector.
  14. Disconnect the oil pressure sensor connector.
  15. Disconnect the left hand CMP sensor connector.
  16. Remove the stud bolt and the left hand radio ignition interference capacitor.
  17. Disconnect the 4 left hand ignition coil connectors.
  18. Remove the 8 bolts and the 8 ignition coils.
  19. Disconnect the Crankshaft Position (CKP) sensor connector.
  20. Remove the engine wiring harness from the engine assembly.
  21. Remove the bolt and the oil level indicator tube and discard the O-ring seal.
  22. Remove the bolt and the right hand CMP sensor.
  23. Remove the bolt and the left hand CMP sensor.
  24. Remove the bolt and the CKP sensor.
    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 old sealant.


    CAUTION
    When removing the valve cover, make sure to avoid damaging the variable camshaft timing (VCT) solenoid.


    NOTE
    The bolts are part of the valve cover and should not be removed.
  25. Remove the bolts and the valve covers.
  26. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep.
  27. Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
  28. Remove the bolts, the coolant pump pulley and the 3 accessory drive belt idler pulleys.
  29. Remove the bolts and the accessory drive belt tensioner.
  30. Remove and discard the crankshaft pulley bolt. Using tool 303-009, remove the crankshaft pulley.
  31. Using the tool 303-107, remove the crankshaft seal.
  32. Remove the front 4 oil pan bolts.
    NOTE
    Correct fastener location is essential for assembly procedure. Record fastener location.
  33. Remove the engine front cover fasteners and the cover.
  34. Remove the crankshaft sensor ring from the crankshaft.
  35. Position the crankshaft keyway at the 12 o'clock position.
    NOTE
    f the camshaft lobes are not exactly positioned at the 12 o'clock position, the crankshaft will require one full additional rotation to 12 o'clock. The number 1 cylinder camshaft exhaust lobe must be coming up on the exhaust stroke. Verify by noting the position of the 2 intake camshaft lobes and the exhaust lobe on the number 1 cylinder.


    NOTE
    If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original locations.
  36. Remove only the 3 roller followers shown in the illustration from the right hand cylinder head. 
    CAUTION
    Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder.


    NOTE
    It may be necessary to push the valve down while compressing the spring.


    image

    Fig. Remove only the 3 roller followers shown from the right hand cylinder head
  37. Using the tool illustrated, remove the 3 designated roller followers in the previous step from the right hand cylinder head.

    Click image to see an enlarged view
    Fig. Using the tool illustrated, remove the 3 designated roller followers
  38. Remove only the 3 roller followers shown in the illustration from the left hand cylinder head.

    Click image to see an enlarged view
    Fig. Remove only the 3 roller followers shown from the left hand cylinder head
  39. Using the tool 303-1039, remove the 3 designated roller followers in the previous step from the left hand cylinder head.
  40. The crankshaft cannot be moved past the 6 o'clock position once set.
  41. Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.
    CAUTION
    If one or both of the tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.
  42. Remove the bolts, the left hand timing chain tensioner and tensioner arm.
  43. Remove the bolts, the right hand timing chain tensioner and tensioner arm.
  44. Remove the right hand and left hand timing chains and the crankshaft sprocket.
  45. Remove the right hand timing chain from the camshaft sprocket.
  46. Remove the right hand timing chain from the crankshaft sprocket.
  47. Remove the left hand timing chain from the camshaft sprocket.
  48. Remove the left hand timing chain and crankshaft sprocket.
  49. Remove the left hand and right hand timing chain guides.
    CAUTION
    Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.


    CAUTION
    Only use hand tools to remove the camshaft phaser sprocket assembly or damage may occur to the camshaft or camshaft phaser unit.


    CAUTION
    Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.
  50. Using the tool illustrated, remove the bolt and the right hand camshaft phaser sprocket assembly. Discard the camshaft phaser sprocket bolt.

    Click image to see an enlarged view
    Fig. Remove the bolt and the right hand camshaft phaser sprocket assembly
  51. Using tool 303-1046, remove the bolt and the left hand camshaft phaser sprocket assembly. Discard the camshaft phaser sprocket bolt.
    CAUTION
    When removing the front thrust camshaft bearing cap, use care as the cap may be damaged from side loading when removing the cam unequally in height from the bearing towers.


    NOTE
    The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations.
  52. Remove the bolts in the sequence shown and remove the right hand cylinder head front camshaft bearing cap and then the remaining bearing caps.

    Click image to see an enlarged view
    Fig. Right side bearing cap removal and tightening sequence, left side similar
  53. Clean and inspect the right hand camshaft bearing caps.
  54. The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.
  55. Remove the right hand camshaft.
  56. Remove the bolts in the sequence shown and remove the left hand cylinder head front camshaft bearing cap and then the remaining bearing caps.
  57. Clean and inspect the left hand camshaft bearing caps.
  58. The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.
  59. Remove the left hand camshaft.
    CAUTION
    If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original locations.
  60. Remove the all of the remaining roller followers from the cylinder heads.
  61. Remove the hydraulic lash adjusters from the cylinder heads.
  62. Install the tool illustrated onto the cylinder head.

    Click image to see an enlarged view
    Fig. Install the tool illustrated onto the left or right hand cylinder head
  63. Remove the exhaust manifold. Discard the gasket.
  64. Remove the stud bolt and the coolant tube. Discard the O-ring seals.
    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 must be 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.
  65. Remove the bolts and the cylinder head.
  66. Discard the cylinder head gasket and bolts.
To install:

CAUTION
Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore.


CAUTION
The use of sealing aids (aviation cement, copper spray, and glue) is not permitted. The gasket must be installed dry.


NOTE
Do not turn the crankshaft until instructed to do so.

  1. Position the cylinder head gaskets and cylinder heads over the dowels and install the cylinder head bolts loosely.
  2. Tighten the bolts in three steps, in the sequence shown as follows:
    1. Step 1: Tighten to 30 ft. lbs. (40 Nm).
    2. Step 2: Tighten an additional 90 degrees.
    3. Step 3: Tighten an additional 90 degrees.
  3. Remove the tool from the left hand cylinder head.
  4. Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.
  5. Install the hydraulic lash adjusters into the left hand cylinder head.
  6. Using a new gasket, install the exhaust manifold.
  7. Install the coolant tube and the stud bolt.
  8. Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.
  9. Install the left hand and right hand camshafts.
  10. Install the left hand and right hand camshaft bearing caps in their original locations.
  11. Lubricate the camshaft bearing caps with clean engine oil.
  12. Install the camshaft bearing cap. Position the remaining camshaft bearing caps. Install the bolts loosely, then tighten to 89 inch lbs. (10 Nm).
    CAUTION
    Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.
  13. Install the camshaft phaser sprockets and new camshaft phaser bolts finger tight.
    CAUTION
    Only use hand tools to remove the camshaft phaser sprocket assembly or damage may occur to the camshaft or camshaft phaser unit.
  14. Using tool 303-1046, tighten the left hand and right hand camshaft phaser sprocket bolts in 2 steps:
    1. Step 1: Tighten to 30 ft. lbs. (40 Nm).
    2. Step 2: Tighten an additional 90 degrees.
      CAUTION
      Timing chain procedures must be followed exactly or damage to valves and pistons will result.


      CAUTION
      Prior to installation, inspect the tensioner-sealing bead for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.
  15. Compress the tensioner plunger, using a vise.
  16. Install a retaining clip on the tensioner to hold the plunger in during installation.
  17. Remove the tensioner from the vise.
  18. If the copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks.

    Click image to see an enlarged view
    Fig. If the copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks


    Click image to see an enlarged view
    Fig. Install the crankshaft sprocket, making sure the flange faces forward
  19. Install the crankshaft sprocket, making sure the flange faces forward.
  20. Install the 4 bolts and the left hand and right hand timing chain guides. Tighten to 89 inch lbs. (10 Nm).
  21. Position the lower end of the left hand (inner) timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single copper (marked) link on the chain.
    NOTE
    Make sure the upper half of the timing chain is below the tensioner arm dowel.



    Click image to see an enlarged view
    Fig. Position the lower end of the left hand (inner) timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single copper (marked) link on the chain


    Click image to see an enlarged view
    Fig. Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the two copper (marked) chain links
  22. Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the two copper (marked) chain links.
    NOTE
    The left hand timing chain tensioner arm has a bump near the dowel hole for identification.
  23. Position the left hand timing chain tensioner arm on the dowel pin and install the left hand timing chain tensioner and bolts. Tighten the bolts to 18 ft. lbs. (25 Nm).
  24. Remove the retaining clip from the left hand timing chain tensioner.
  25. Position the lower end of the right hand (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single copper (marked) chain link.
    NOTE
    The lower half of the timing chain must be positioned above the tensioner arm dowel.



    Click image to see an enlarged view
    Fig. Position the lower end of the right hand (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single copper (marked) chain link


    Click image to see an enlarged view
    Fig. Position the right hand timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is positioned between the two copper (marked) chain links
  26. Position the right hand timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is positioned between the two copper (marked) chain links.
  27. Position the right hand timing chain tensioner arm on the dowel pin and install the right hand timing chain tensioner and bolts. Tighten the bolts to 18 ft. lbs. (25 Nm).
  28. Remove the retaining clip from the right hand timing chain tensioner.
  29. As a final-check, verify correct alignment of all timing marks.

    Click image to see an enlarged view
    Fig. Verify correct alignment of all timing marks
  30. Install the crankshaft sensor ring on the crankshaft.
  31. Lubricate the roller followers with clean engine oil prior to installation.
  32. Using tool 303-1039, install all of the camshaft roller followers.
    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 old sealant.


    NOTE
    If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.


    NOTE
    Make sure that the engine front cover gasket is in place on the engine front cover before installation.
  33. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface, at the locations illustrated.

    Click image to see an enlarged view
    Fig. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface, at the locations shown
  34. Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the fasteners finger-tight.
  35. Tighten the engine front cover fasteners in sequence in 2 steps:
    1. Step 1: Tighten fasteners 1 through 15 to 18 ft. lbs. (25 Nm).
    2. Step 2: Tighten fasteners 6 and 7 to 35 ft. lbs. (48 Nm).
      CAUTION
      Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.



      Click image to see an enlarged view
      Fig. Engine front cover fastener location and torque sequence
  36. Clean the valve cover mating surface with silicone gasket remover and metal surface prep.
  37. Install the 4 front oil pan bolts in the sequence shown in 2 steps.
    1. Step 1: Tighten to 15 ft. lbs. (20 Nm).
    2. Step 2: Tighten an additional 60 degrees.
      NOTE
      If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.



      Click image to see an enlarged view
      Fig. Front oil pan bolts torque sequence
  38. Apply a 0.32 inch (8mm) bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
    CAUTION
    When installing the valve cover, make sure to avoid damaging the Variable Camshaft Timing (VCT) solenoid.



    Click image to see an enlarged view
    Fig. Apply a 0.32 inch (8mm) bead of silicone gasket and sealant in 2 places where the engine front cover meets the right cylinder head
  39. Install the right hand valve cover and gasket on the cylinder head and tighten the bolts in the sequence shown and tighten to 89 inch lbs. (10 Nm).
    NOTE
    If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.



    Click image to see an enlarged view
    Fig. Install the right hand valve cover and gasket on the cylinder head and tighten the bolts in sequence
  40. Apply a 0.32 inch (8mm) bead of silicone gasket and sealant in 2 places where the engine front cover meets the left cylinder head.

    Click image to see an enlarged view
    Fig. Apply a 0.32 inch (8mm) bead of silicone gasket and sealant in 2 places where the engine front cover meets the left cylinder head
  41. Install the left hand valve cover and gasket on the cylinder head and tighten the bolts in the sequence shown and tighten to 89 inch lbs. (10 Nm).

    Click image to see an enlarged view
    Fig. Install the left hand valve cover and gasket on the cylinder head and tighten the bolts in sequence
  42. Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil.
  43. Use the tools illustrated to install the crankshaft seal into the engine front cover.
    NOTE
    If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.



    Click image to see an enlarged view
    Fig. Install the crankshaft seal into the engine front cover
  44. Apply a 0.32 inch (8mm) bead of silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.

    Click image to see an enlarged view
    Fig. Apply a 0.32 inch (8mm) bead of silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley


    Click image to see an enlarged view
    Fig. Install the crankshaft pulley
  45. Use the tool illustrated to install the crankshaft pulley.
  46. Tighten the new crankshaft pulley bolt in 4 steps
    1. Step 1: Tighten to 66 ft. lbs. (90 Nm).
    2. Step 2: Loosen 360 degrees.
    3. Step 3: Tighten to 37 ft. lbs. (50 Nm).
    4. Step 4: Tighten an additional 90 degrees.
      NOTE
      Lubricate the new O-ring seal with clean engine oil prior to installation.
  47. Install the left hand CMP sensor and the bolt.
    NOTE
    Lubricate the new O-ring seal with clean engine oil prior to installation.
  48. Install the right hand CMP sensor and the bolt.
  49. Install the CKP sensor and the bolt.
  50. Install the accessory drive belt tensioner and install the 3 bolts. Tighten the bolts to 18 ft. lbs. (25 Nm).
  51. Install the 3 accessory drive belt idler pulleys, the coolant pump pulley and the 7 bolts. Tighten the bolts to 18 ft. lbs. (25 Nm).
  52. Position the electrical harness on the engine assembly and connect the engine wiring harness retainers to the valve cover studs.
  53. Connect the CKP sensor connector.
  54. Install the 8 ignition coils and the 8 bolts.
  55. Connect the 4 left hand ignition coil connectors.
  56. Install the left hand radio ignition interference capacitor and the stud bolt. Tighten the bolt to 18 ft. lbs. (25 Nm).
  57. Connect the left hand CMP sensor connector.
  58. Connect the engine oil pressure sensor connector.
  59. Connect the left hand VCT solenoid connector.
  60. Connect the 2 engine wiring harness retainers to the left hand valve cover studs.
  61. Connect the CHT sensor connector.
  62. Connect the 4 right hand ignition coil connectors.
  63. Connect the connector retainer to the coolant tube.
  64. Connect the 2 engine wiring harness retainers to the right hand valve cover studs.
  65. Connect the right hand VCT solenoid connector.
  66. Install the right hand radio ignition interference capacitor and the stud bolt. Tighten the bolt to 18 ft. lbs. (25 Nm).
  67. Connect the right hand CMP sensor connector.
  68. Using a suitable floor crane, remove the engine from the engine stand.
  69. Install the flexplate and the 8 bolts in a star pattern. Tighten the bolts to 59 ft. lbs. (80 Nm).
  70. Install the engine.


These details will help.
Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

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



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