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How to replace Cylinder Head on Ford Taurus And Mercury Sable?

The above details are for year 2008 and 2009 ford Taurus and Mercury Sable.

The procedure is same for both.


Cylinder Head
REMOVAL & INSTALLATION

Details are as follows :----

Left Side
Specific to:
Ford Taurus 2008-2009
Mercury Sable 2008-2009

NOTE
During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.

  1. Remove the LH camshafts. Refer to Camshaft.
  2. Disconnect the 6 fuel injector electrical connectors (3 shown).
  3. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
  4. Disconnect the LH camshaft position (CMP) sensor electrical connector.
  5. Remove the bolt and the LH CMP sensor.
  6. Disconnect the LH heated oxygen sensor (HO2S) electrical connector.
  7. Disconnect the LH catalyst monitor sensor electrical connector.
  8. Detach the wiring harness retainer from the rear of the LH cylinder head.
  9. Remove the nut and disconnect the generator B+ cable.
  10. Disconnect the generator electrical connector.
  11. Remove the nut, bolt and the generator.
  12. Remove the generator stud.
  13. Detach the engine oil pressure (EOP) switch wiring harness pin-type retainer.
  14. Remove the 2 LH catalytic converter bracket bolts.
  15. Remove the 4 nuts and the LH catalytic converter. Discard the nuts and the gasket.
  16. Remove the 3 bolts and the LH exhaust manifold heat shield.
  17. Remove the 6 nuts and the LH exhaust manifold. Discard the nuts and the exhaust manifold gasket.
  18. Clean and inspect the LH exhaust manifold.
  19. Remove and discard the 6 LH exhaust manifold studs.
  20. Remove the LH cylinder block drain plug. Allow coolant to drain from the cylinder block.
  21. Remove the 4 nuts and the RH catalytic converter. Discard the nuts and gasket.
  22. If equipped, remove the heat shield and disconnect the block heater electrical connector. Remove the block heater wiring harness from the engine.
  23. Remove the RH cylinder block drain plug or, if equipped, the block heater. Allow coolant to drain from the cylinder block.
  24. Remove the coolant bypass hose from the thermostat housing.
  25. Remove the 4 bolts and the fuel rail and injectors as an assembly.
  26. Remove the 3 thermostat housing-to-lower intake manifold bolts.
  27. Remove the thermostat housing and discard the gasket and O-ring seal.
  28. Remove the 10 bolts and the lower intake manifold. Discard the gaskets.
  29. Remove the 2 bolts and the upper LH primary timing chain guide.
  30. Remove the 2 bolts and the LH secondary timing chain tensioner.
    NOTE
    If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations.
  31. Remove the valve tappets from the cylinder head.
  32. Inspect the valve tappets.
  33. Remove and discard the M6 bolt at the front of the head.
    NOTE
    Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.


    NOTE
    Aluminum surfaces are soft and may be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.


    NOTE
    The cylinder head bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused.
  34. Remove and discard the 8 bolts from the cylinder head.
  35. Remove the cylinder head. Discard the cylinder head gasket.
    NOTE
    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.


    NOTE
    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.
  36. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder heads and the cylinder block in the following sequence.
    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.
  37. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion.
To install:
  1. Install a new gasket, the LH cylinder head and 8 new bolts. Tighten in the sequence shown in 5 stages:
    1. Stage 1: Tighten to 15 ft. lbs. (20 Nm).
    2. Stage 2: Tighten to 26 ft. lbs. (35 Nm).
    3. Stage 3: Tighten 90 degrees.
    4. Stage 4: Tighten 90 degrees.
    5. Stage 5: Tighten 90 degrees.

      Click image to see an enlarged view
      Fig. Left cylinder head tightening sequence
  2. Install the M6 bolt at the front of the head. Tighten to 89 inch lbs. (10 Nm).
    NOTE
    The valve tappets must be installed in their original positions.


    NOTE
    Coat the valve tappets with clean engine oil prior to installation.
  3. Install the valve tappets.
  4. Install the LH secondary timing chain tensioner and the 2 bolts. Tighten to 89 inch lbs. (10 Nm).
  5. Install the upper LH primary timing chain guide and the 2 bolts. Tighten to 89 inch lbs. (10 Nm).
  6. Using new gaskets, install the lower intake manifold and the 10 bolts. Tighten in the sequence shown to 89 inch lbs. (10 Nm).

    Click image to see an enlarged view
    Fig. Lower intake manifold tightening sequence
  7. Using a new gasket and O-ring seal, install the thermostat housing and the 3 bolts. Tighten to 89 inch lbs. (10 Nm).
    NOTE
    Use O-ring seals that are made of special fuel-resistant material. The use of ordinary O-rings may cause the fuel system to leak. Do not reuse the O-ring seals.


    NOTE
    The upper and lower O-ring seals are not interchangeable.
  8. Install new fuel injector O-ring seals.
  9. Remove the retaining clips and separate the fuel injectors from the fuel rail.
  10. Remove and discard the O-ring seals.
  11. Install new O-ring seals and lubricate with clean engine oil.
  12. Install the fuel injectors and the retaining clips onto the fuel rail.
  13. Install the fuel rail and injectors as an assembly and install the 4 bolts. Tighten to 89 inch lbs. (10 Nm).
  14. Install the coolant bypass hose to the thermostat housing.
  15. Install the RH cylinder block drain plug or, if equipped, the block heater. Tighten to 30 ft. lbs. (40 Nm).
  16. If equipped, install the block heater wiring harness onto the engine. Connect the block heater electrical connector and install the heat shield.
  17. Using a new gasket, install the RH catalytic converter and 4 new nuts. Tighten to 30 ft. lbs. (40 Nm).
  18. Install the LH cylinder block drain plug. Tighten to 15 ft. lbs. (20 Nm) plus an additional 180 degrees.
  19. Install 6 new LH exhaust manifold studs. Tighten to 106 inch lbs. (12 Nm).
    NOTE
    Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.
  20. Using a new gasket, install the LH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown:
    1. Stage 1: Tighten to 15 ft. lbs. (20 Nm).
    2. Stage 2: Tighten to 15 ft. lbs. (20 Nm).

      Click image to see an enlarged view
      Fig. Left exhaust manifold tightening sequence
  21. Install the LH exhaust manifold heat shield and the 3 bolts. Tighten to 10 ft. lbs. (14 Nm).
  22. Using a new gasket, install the LH catalytic converter and 4 new nuts. Tighten to 30 ft. lbs. (40 Nm).
  23. Install the LH catalytic converter bracket bolts. Tighten to 15 ft. lbs. (20 Nm).
  24. Attach the engine oil pressure (EOP) switch wiring harness pin-type retainer.
  25. Install the stud, generator and the nut and bolt. Tighten the stud to 106 inch lbs. (12 Nm). Tighten nut and bolt to 35 ft. lbs. (48 Nm).
  26. Connect the generator electrical connector.
  27. Connect the generator B+ cable and install the nut. Tighten to 53 inch lbs. (6 Nm).
  28. Attach the pin-type wire harness retainer to the rear of LH cylinder head.
  29. Connect the LH catalyst monitor sensor electrical connector.
  30. Connect the LH heated oxygen sensor (HO2S) electrical connector.
  31. Install LH camshaft position (CMP) sensor and the bolt. Tighten to 89 inch lbs. (10 Nm).
  32. Connect the LH CMP sensor electrical connector.
  33. Connect the cylinder head temperature (CHT) sensor electrical connector.
  34. Connect the 6 fuel injector electrical connectors.
  35. Install the LH camshafts. Refer to Camshaft.
Right Side
Specific to:
Ford Taurus 2008-2009
Mercury Sable 2008-2009
  1. Remove the RH camshafts. Refer to Camshaft.
  2. Disconnect the RH heated oxygen sensor (HO2S) electrical connector.
  3. Disconnect the RH camshaft position (CMP) sensor electrical connector.
  4. Remove the bolt and the RH CMP sensor.
  5. Remove the bolt and the power steering pressure (PSP) tube bracket from the RH cylinder head.
  6. Remove the bolt and the ground wire.
  7. Disconnect the 6 fuel injector electrical connectors.
  8. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
  9. Disconnect the LH catalyst monitor sensor electrical connector.
  10. Remove the 2 LH catalytic converter bracket bolts.
  11. Remove the 4 nuts and the LH catalytic converter. Discard the nuts and the gasket.
  12. Remove the LH cylinder block drain plug.
  13. Allow coolant to drain from the cylinder block.
  14. Remove the 4 nuts and the RH catalytic converter. Discard the nuts and gasket.
  15. If equipped, remove the heat shield and disconnect the block heater electrical connector. Remove the block heater wiring harness from the engine.
  16. Remove the RH cylinder block drain plug or, if equipped, the block heater.
  17. Allow coolant to drain from the cylinder block.
  18. Remove the 3 bolts and the RH exhaust manifold heat shield.
  19. Remove the 6 nuts and the RH exhaust manifold. Discard the nuts and exhaust manifold gaskets.
  20. Clean and inspect the RH exhaust manifold.
  21. Remove and discard the 6 RH exhaust manifold studs.
  22. Remove the 2 bolts and the RH primary timing chain guide.
  23. Remove the bolts and the RH secondary timing chain tensioner.
  24. Remove the 2 bolts and the engine lifting eye.
    NOTE
    Index-mark the location of the bracket on the cylinder head for installation.
  25. If equipped, remove the bolt and the upper intake manifold long support bracket.
    NOTE
    Index-mark the location of the bracket on the cylinder head for installation.
  26. Remove the bolt and the upper intake manifold short support bracket.
  27. Remove the coolant by-pass hose from the thermostat housing.
  28. Remove the 4 bolts and the fuel rail and injectors as an assembly.
  29. Remove the 3 thermostat housing-to-lower intake manifold bolts.
  30. Remove the thermostat housing and discard the gasket and O-ring seal.
  31. Remove the 10 bolts and the lower intake manifold. Discard the gaskets.
  32. Disconnect and remove the CHT sensor jumper harness.
    NOTE
    If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations.
  33. Remove the valve tappets from the cylinder head.
  34. Inspect the valve tappets.
  35. Remove and discard the M6 bolt from front of head.
    NOTE
    Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.


    NOTE
    Aluminum surfaces are soft and may be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.


    NOTE
    The cylinder head bolts must be discarded and new bolts must be installed. They are tighten-to-yield design and cannot be reused.
  36. Remove and discard the 8 bolts from the cylinder head.
  37. Remove the cylinder head. Discard the cylinder head gasket.
    NOTE
    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.


    NOTE
    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.
  38. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder heads and the cylinder block in the following sequence.
    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.
  39. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion.
To install:
  1. Install a new gasket, the RH cylinder head and 8 new bolts. Tighten in the sequence shown in 5 stages:
    1. Stage 1: Tighten to 15 ft. lbs. (20 Nm).
    2. Stage 2: Tighten to 26 ft. lbs. (35 Nm).
    3. Stage 3: Tighten 90 degrees.
    4. Stage 4: Tighten 90 degrees.
    5. Stage 5: Tighten 90 degrees.

      Click image to see an enlarged view
      Fig. Right cylinder head tightening sequence
  2. Install the M6 bolt at the front of the head. Tighten to 89 inch lbs. (10 Nm).
    NOTE
    The valve tappets must be installed in their original positions.


    NOTE
    Coat the valve tappets with clean engine oil prior to installation.
  3. Install the valve tappets.
  4. Install and connect the cylinder head temperature (CHT) sensor jumper harness.
  5. Using new gaskets, install the lower intake manifold and the 10 bolts. Tighten in the sequence shown to 89 inch lbs. (10 Nm).

    Click image to see an enlarged view
    Fig. Lower intake manifold tightening sequence
  6. Using a new gasket and O-ring seal, install the thermostat housing and the 3 bolts. Tighten to 89 inch lbs. (10 Nm).
    NOTE
    Use O-ring seals that are made of special fuel-resistant material. The use of ordinary O-rings may cause the fuel system to leak. Do not reuse the O-ring seals.


    NOTE
    The upper and lower O-ring seals are not interchangeable.
  7. Install new fuel injector O-ring seals.
  8. Remove the retaining clips and separate the fuel injectors from the fuel rail.
  9. Remove and discard the O-ring seals.
  10. Install new O-ring seals and lubricate with clean engine oil.
  11. Install the fuel injectors and the retaining clips onto the fuel rail.
  12. Install the fuel rail and injectors as an assembly and install the 4 bolts. Tighten to 89 inch lbs. (10 Nm).
  13. Install the coolant bypass hose to the thermostat housing.
    NOTE
    Align the bracket with the index mark made during removal.
  14. Install the upper intake manifold short support bracket and the bolt. Tighten to 89 inch lbs. (10 Nm).

  15. NOTE
    Align the bracket with the index mark made during removal.
  16. If equipped, install the upper intake manifold long support bracket and the bolt. Tighten to 89 inch lbs. (10 Nm).
  17. Install the engine lifting eye and the 2 bolts. Tighten to 18 ft. lbs. (24 Nm).
  18. Install the RH secondary timing chain tensioner and the 2 bolts. Tighten to 89 inch lbs. (10 Nm).
  19. Install the RH primary timing chain guide and the 2 bolts. Tighten to 89 inch lbs. (10 Nm).
  20. Install 6 new RH exhaust manifold studs. Tighten to 106 inch lbs. (12 Nm).
    NOTE
    Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.
  21. Using a new gasket, install the RH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown:
    1. Stage 1: Tighten to 15 ft. lbs. (20 Nm).
    2. Stage 2: Tighten to 15 ft. lbs. (20 Nm).

      Click image to see an enlarged view
      Fig. Right exhaust manifold tightening sequence
  22. Install the RH exhaust manifold heat shield and the 3 bolts. Tighten to 10 ft. lbs. (14 Nm).
  23. Install the RH cylinder block drain plug or, if equipped, the block heater. Tighten to 30 ft. lbs. (40 Nm).
  24. If equipped, install the block heater wiring harness onto the engine. Connect the block heater electrical connector and install the heat shield.
  25. Using a new gasket, install the RH catalytic converter and 4 new nuts. Tighten to 30 ft. lbs. (40 Nm).
  26. Install the LH cylinder block drain plug. Tighten to 15 ft. lbs. (20 Nm) plus an additional 180 degrees.
  27. Using a new gasket, install the LH catalytic converter and 4 new nuts. Tighten to 30 ft. lbs. (40 Nm).
  28. Install the 2 LH catalytic converter bracket bolts. Tighten to 15 ft. lbs. (20 Nm).
  29. Connect the LH catalyst monitor sensor electrical connector.
  30. Connect the CHT sensor electrical connector.
  31. Connect the 6 fuel injector electrical connectors.
  32. Install the ground wire and the bolt. Tighten to 89 inch lbs. (10 Nm).
  33. Install the Power Steering Pressure (PSP) tube bracket and the bolt to the RH cylinder head. Tighten to 89 inch lbs. (10 Nm).
  34. Install the RH camshaft position (CMP) sensor and the bolt. Tighten to 89 inch lbs. (10 Nm).
  35. Connect the RH CMP sensor electrical connector.
  36. Connect the RH heated oxygen sensor (HO2S) electrical connector.
  37. Install the RH camshafts. Refer to Camshaft.


This will help.
Thanks.



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