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Cylinder Head Replacing Procedure for 4.6L engine?


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

Cylinder Head
REMOVAL & INSTALLATION

F150 1/2 ton P/U 2WD/ 4WD
F250 Super Duty P/U 2WD/4WD
F350 Super Duty P/U 2WD/4WD
F450 Super Duty P/U 2WD/4WD
F550 Super Duty P/U 2WD/4WD
AND Lincoln Mark LT Models


4.6L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Remove the engine. See -Engine Assembly- in this section.
  3. Remove the bolts and the flexplate or the flywheel.
  4. Install the engine onto a suitable engine stand.
  5. Remove the 3 bolts and the RH engine support insulator.
  6. Remove the cylinder block drain plugs and drain the coolant into a suitable container. Reinstall the cylinder block drain plugs.
  7. Remove or disconnect the following:

    Engine oil pressure (EOP) sensor electrical connector
    Knock sensor (KS) electrical connector and the wiring harness pin-type retainer
    Camshaft position (CMP) sensor electrical connector
    Crankshaft position (CKP) sensor electrical connector
    Upper radiator hose bracket.
    LH radio ignition interference capacitor and cylinder head temperature (CHT) sensor electrical connectors
    RH radio ignition interference capacitor electrical connector
    Engine wiring harness retainers from the valve cover studs and remove the electrical harness from the engine assembly
    2 radio interference capacitors
    CMP sensor and the CKP sensor
    Valve covers
    Accessory drive belt tensioner
    Crankshaft pulley bolt and washer (discard the bolt)
    Crankshaft pulley
    Crankshaft front seal
    4 front oil pan bolts
  8. Remove the engine front cover bolts engine and front cover from the front cover to cylinder.
  9. Remove the 8 spark plugs.
  10. Install the special tool between the valve spring coils to prevent valve stem seal damage. 
    image
    Fig. Install the special tool between the valve spring coils to prevent valve stem seal damage
  11. The camshaft roller followers must be reinstalled in their original locations. Record the camshaft roller follower locations.
    NOTE
    Position the cam lobe away from the camshaft roller follower prior to removing each camshaft roller follower.
  12. Using the special tool, compress the valve springs and remove the camshaft roller followers.

    Click image to see an enlarged view
    Fig. Using the special tool, compress the valve springs and remove the camshaft roller followers
  13. Repeat the previous steps for each of the roller followers.
  14. Remove the crankshaft sensor ring from the crankshaft.

    Click image to see an enlarged view
    Fig. Remove the crankshaft sensor ring from the crankshaft
  15. Rotate the crankshaft until the timing mark on the RH camshaft sprocket is approximately at the 11 o'clock position and the timing mark on the LH camshaft sprocket is approximately at the 12 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.



    Click image to see an enlarged view
    Fig. Rotate the crankshaft until the timing mark on the RH camshaft sprocket is approximately at the 11 o'clock position and the timing mark on the LH camshaft sprocket is approximately at the 12 o'clock position
  16. Remove the timing chain tensioning system from both timing chains.
  17. Remove the bolts and the timing chain tensioners.
  18. Remove the timing chain tensioner arms.
  19. Remove the timing chains and crankshaft sprocket.
  20. Remove the 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.
LH cylinder head
  1. Remove the LH exhaust manifold.
  2. Remove the bolt and the oil level indicator tube.
RH cylinder head
  1. Remove the RH exhaust manifold.
  2. Disconnect the coolant hoses from the heater outlet tube and studs.
  3. Remove the heater outlet tube and discard the O-ring seal.
All cylinder heads
  1. Install the special lifting handles on both ends of the cylinder head being serviced.
    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.
  2. Remove the bolts and the cylinder head. Discard the gasket and bolts.
    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.
  3. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block.
  4. Remove any large deposits of silicone or gasket material with a plastic scraper.
  5. Apply silicone gasket remover, following package directions, and allow to set for several minutes.
  6. 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.
  7. 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.
    NOTE
    Make sure all cylinder head surfaces are clear of any gasket material, RTV, oil and coolant. The cylinder head surface must be clean and dry before running a flatness check.


    NOTE
    Use a straightedge that is calibrated by the manufacturer to be flat with 0.005 mm (0.0002 in) per running foot length. For example, if the straightedge is 61 cm (24 in) long, the machine edge must be flat with 0.010 mm (0.0004 in) from end to end.
  8. 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).

    Click image to see an enlarged view
    Fig. Inspect the oil feed areas, as indicated; also inspect the cylinder head for warpage
To install:
All cylinder heads  

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


WARNING
The use of sealing aids. The gasket must be installed dry.  


WARNING
The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.



Click image to see an enlarged view
Fig. Dowel installation

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

  1. Using the lifting tools, position the cylinder head gaskets and cylinder heads over the dowels and install the cylinder head bolts loosely.
  2. Tighten the bolts in the sequence shown.
    1. Stage 1: Tighten to 40 Nm (30 ft. lbs.).
    2. Stage 2: Tighten an additional 90 degrees.
    3. Stage 3: Tighten an additional 90 degrees.

      Click image to see an enlarged view
      Fig. Showing the LH cylinder head bolt tightening sequence


      Click image to see an enlarged view
      Fig. Showing the RH cylinder head bolt tightening sequence
All cylinder heads  

WARNING
Timing chain procedures must be followed exactly or damage to valves and pistons will result.

  1. Compress the tensioner plunger, using a vise.
  2. Install a retaining clip on the tensioner to hold the plunger in during installation.

    Click image to see an enlarged view
    Fig. Plunger held by a retaining clip
  3. Remove the tensioner from the vise. If the copper links are not visible, mark one link 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 one link on one end and one link on the other end, and use as timing marks
  4. Install the crankshaft sprocket, making sure the flange faces forward.

    Click image to see an enlarged view
    Fig. Install the crankshaft sprocket, making sure the flange faces forward
  5. Position the left timing chain guide.

    Click image to see an enlarged view
    Fig. Timing chain guide installation
  6. Install and tighten the left bolts.
  7. Position the right timing chain guide.
  8. Install and tighten the right bolts.
  9. Rotate the right camshaft sprocket until the timing mark is approximately at the 11 o'clock position. Rotate the left camshaft sprocket until the timing mark is approximately at the 12 o'clock position.
    NOTE
    The number one cylinder is at top dead center (TDC) when the stud on the engine block fits into the slot in the handle of the special tool.



    Click image to see an enlarged view
    Fig. Crankshaft alignment tool installed
  10. Position the crankshaft so the number one cylinder is at TDC with the special tool.
  11. Remove the Crankshaft Holding Tool.
  12. Position the left (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.

    Click image to see an enlarged view
    Fig. Position the left (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket
  13. Install the left timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
    NOTE
    The left timing chain tensioner arm has a bump near the dowel hole for identification.



    Click image to see an enlarged view
    Fig. Install the left timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket
  14. Position the left timing chain tensioner arm on the dowel pin and install the left timing chain tensioner.
  15. Remove the retaining clip from the left timing chain tensioner. Torque to 18 ft. lbs. (25 Nm).
  16. Position the right (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.

    Click image to see an enlarged view
    Fig. Position the right (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket
  17. Install the right timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.

    Click image to see an enlarged view
    Fig. Install the right timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket
  18. Position the right timing chain tensioner arm on the dowel pin and install the right timing chain tensioner. Torque to 18 ft. lbs. (25 Nm).
  19. Remove the retaining clip from the right timing chain tensioner. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.
  20. Install the crankshaft sensor ring on the crankshaft.  
    WARNING
    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 four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. 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.
  21. 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.

    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
  22. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.

    Click image to see an enlarged view
    Fig. Front cover fastener tightening sequence
  23. Tighten the engine front cover fasteners in sequence in three stages.
    1. Stage 1: Tighten fasteners 1 through 5 to 25 Nm (18 ft. lbs.).
    2. Stage 2: Tighten fasteners 6 and 7 to 25 Nm (18 ft. lbs.).
    3. Stage 3: Tighten fasteners 8 through 15 to 25 Nm (18 ft. lbs.).
  24. Install the left camshaft position (CMP) sensor and the bolt.
  25. Lubricate the new O-ring seal with clean engine oil prior to installation.
  26. Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil. Use a driver to install the crankshaft seal into the engine front cover.
    NOTE
    If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
  27. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley. Use the special tool to install the crankshaft pulley.
  28. Tighten the new crankshaft pulley bolt in four stages.
    1. Stage 1: Tighten to 90 Nm (66 ft. lbs.).
    2. Stage 2: Loosen 360 degrees.
    3. Stage 3: Tighten to 50 Nm (37 ft. lbs.).
    4. Stage 4: Tighten an additional 90 degrees.
  29. Install the three accessory drive belt idler pulleys, the coolant pump pulley and the bolts.
  30. Position the accessory drive belt tensioner and install the bolts.
  31. Install a suitable tool between the valve spring coils to prevent valve stem seal damage.
    NOTE
    The camshaft roller followers must be reinstalled in their original locations.


    NOTE
    Position the cam lobe away from the valve stem prior to installing each camshaft roller follower.
  32. Use a suitable tool to compress the valve springs, and install the camshaft roller follower. Remove the special tool.
    NOTE
    The camshaft roller followers must be reinstalled in their original locations.
  33. Repeat the previous four steps for each of the camshaft roller followers.
  34. Install the radio frequency interference capacitors.
Left cylinder head  

WARNING
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.

  1. Inspect and clean the valve cover sealing surfaces with metal surface cleaner.
  2. Apply instant adhesive completely around the gasket groove in the left valve cover.
  3. Install the new valve cover gasket.
    NOTE
    If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep.
  4. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
  5. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.

    Click image to see an enlarged view
    Fig. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head
  6. Position the left valve cover and gasket on the cylinder head and install the bolts loosely.
  7. Tighten the valve cover bolts in the sequence shown.
    NOTE
    Lubricate the O-ring seal with clean engine oil.



    Click image to see an enlarged view
    Fig. Tighten the valve cover bolts in the sequence shown
  8. Install the oil level indicator tube.
  9. Install a new O-ring seal on the oil level indicator tube.
  10. Install the oil level indicator tube.
  11. Install the bolt.
  12. Install the left exhaust manifold and the exhaust manifold gasket. Tighten the nuts in the sequence shown.

    Click image to see an enlarged view
    Fig. Install the left exhaust manifold nuts in the sequence shown
Right cylinder head  

WARNING
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.

  1. Inspect and clean the valve cover sealing surfaces with metal surface cleaner.
  2. Apply instant adhesive completely around the gasket groove in the right valve cover. Install the new valve cover gasket.
    NOTE
    If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
  3. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
  4. Position the right valve cover and gasket on the cylinder head and install the bolts loosely.
  5. Tighten the valve cover bolts in the sequence shown.
  6. Install the right exhaust manifold gaskets and the exhaust manifold. Tighten the nuts in the sequence shown.
  7. Slide the heater outlet tube forward with a new O-ring seal into the cylinder block. Lubricate the O-ring seal with engine coolant.
  8. Install the heater outlet tube studs.
  9. Connect the coolant hoses to the heater outlet tube.
All cylinder heads
  1. Connect the right radio ignition interference capacitor electrical connector.
  2. Connect the left radio ignition interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
  3. Connect the CMP sensor electrical connectors.
  4. Connect the CKP sensor electrical connector.
  5. Install a suitable tool.
  6. Using a suitable floor crane, remove the engine from the engine stand.
  7. Install the flexplate or the flywheel and bolts. Tighten the bolts in the sequence shown.
  8. 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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