Continental 2000-2002

Cylinder Head 2

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the engine from the vehicle and mount it on a suitable workstand.
  4.  
  5. Remove or disconnect the following:

    Accessory drive belt and tensioner
     
    Idler pulley
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Water bypass tube
     
    Alternator
     
    Water pump
     
    Power steering pump
     
    Crankshaft pulley
     
    Camshaft Position (CMP) sensor
     
    Ignition coils
     
    Fuel pressure sensor connector and vacuum line
     
    Valve covers
     
    Rocker arms
     
    Exhaust Gas Recirculation (EGR) vacuum regulator valve
     
    EGR tube
     
    Injector wiring connectors
     
    Intake manifold
     
    Left and right exhaust manifolds
     
    Front cover
     
    Crankshaft Position (CKP) sensor pulse wheel
     
    Timing chains
     
    Cylinder heads
     

  6.  

To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-4.6L engine


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

  1. Use new gaskets and install the cylinder heads. Tighten the cylinder head bolts in sequence as follows:
    1. Step 1: 28-31 ft. lbs. (37-43 Nm).
    2.  
    3. Step 2: Tighten the bolts 85-95 degrees.
    4.  
    5. Step 3: Loosen all bolts 1 full turn.
    6.  
    7. Step 4: Tighten all bolts to 28-31 ft. lbs. (37-43 Nm).
    8.  
    9. Step 5: Tighten the bolts 85-95 degrees.
    10.  
    11. Step 6: Tighten the bolts 85-95 degrees.
    12.  

  2.  
  3. Install or connect the following:

    Timing chains
     
    CKP sensor pulse wheel
     
    Front cover
     
    Left and right exhaust manifolds
     
    Intake manifold
     
    Injector wiring connectors
     
    EGR tube
     
    EGR vacuum regulator valve
     
    Rocker arms
     
    Valve covers
     
    Fuel pressure sensor connector and vacuum line
     
    Ignition coils
     
    CMP sensor
     
    Crankshaft pulley
     
    Water pump
     
    Power steering pump
     
    Alternator
     
    Water bypass tube
     
    ECT sensor connector
     
    Idler pulley
     
    Accessory drive belt and tensioner

    Click image to see an enlarged view

    Fig. Right valve cover torque sequence



    Click image to see an enlarged view

    Fig. Left valve cover torque sequence

     

  4.  

3.8L Engine
  1. Drain the cooling system, then disconnect the negative battery cable.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove the air cleaner assembly including air intake duct and heat tube.
  6.  
  7. Loosen the accessory drive belt idler, then remove the drive belt.
  8.  
  9. If the left cylinder head is being removed, perform the following:
    1. Remove the power steering pump. Leave the hoses connected and place the pump/bracket assembly aside in a position to prevent the fluid from leaking out.
    2.  

  10.  



Click image to see an enlarged view

Fig. If you are removing the head to replace the head gasket, remove the pressure and return lines for power steering and leave the pump attached

  1. If equipped with air conditioning, remove mounting bracket attaching bolts. Leaving the hoses connected, position the compressor aside.
  2.  
  3. Remove the alternator and bracket.
  4.  

  1. If the right cylinder head is being removed, perform the following:
    1. Disconnect the thermactor air control valve or bypass valve hose assembly at the air pump.
    2.  
    3. If equipped, disconnect the thermactor tube support bracket from the rear of cylinder head.
    4.  
    5. Remove the accessory drive idler pulley.
    6.  
    7. Remove the PCV valve.
    8.  

  2.  
  3. Remove the upper intake manifold. For details, please refer to the procedure located earlier in this section.
  4.  



Click image to see an enlarged view

Fig. Loosening the 4 center bolts (long) holding the intake manifold in place



Click image to see an enlarged view

Fig. Removing the studs on the outer flanges of the upper intake manifold

  1. Remove the valve/rocker arm cover retaining bolts, then remove the covers.
  2.  
  3. Remove the injector fuel rail assembly.
  4.  



Click image to see an enlarged view

Fig. This fuel rail comes off in one piece, but has 2 different spots with flex hoses

  1. Remove the lower intake manifold and the exhaust manifold(s). For details, please refer to the procedure located earlier in this section.
  2.  



Click image to see an enlarged view

Fig. Removing the lower mounted head bolts. Notice the exhaust manifold has been removed

  1. Loosen the rocker arm fulcrum attaching bolts enough to allow rocker arm to be lifted off the pushrod and rotate to one side. Remove the pushrods. Identify and label the position of each pushrod. Pushrods should be installed in their original position during assembly.
  2.  



Click image to see an enlarged view

Fig. Removing the fulcrum to allow clearance to the head bolts


NOTE
You must use new cylinder head retaining bolts and gaskets when replacing or reinstalling the cylinder head!

  1. Remove the cylinder head attaching bolts and discard. Do NOT reuse the old bolts.
  2.  



Click image to see an enlarged view

Fig. Breaking loose the head bolts with a 1/2 inch breaker



Click image to see an enlarged view

Fig. Removing the head bolts after breaking them loose

  1. Remove the cylinder head(s).
  2.  



Click image to see an enlarged view

Fig. Don't forget the bolts and connectors on the back side of the head. The head won't come off unless you remove them

  1. Remove and discard old cylinder head gasket(s).
  2.  



Click image to see an enlarged view

Fig. Lifting the head off the block, the power steering pump is intact



Click image to see an enlarged view

Fig. With the head removed, inspect and compare the combustion chambers for any differences in appearance



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Fig. Inspect the head gasket for any breaks or tears



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Fig. Check the cooling passages to make sure they are open

To install:

  1. Lightly oil all bolt threads before installation.
  2.  
  3. Clean cylinder head, intake manifold, valve rocker arm cover, and cylinder head gasket contact surfaces. If cylinder head was removed for a cylinder head gasket replacement, check flatness of cylinder head and block gasket surfaces.
  4.  
  5. Position the new head gasket(s) onto cylinder block using dowels for alignment. Position cylinder head(s) onto block.
  6.  



Click image to see an enlarged view

Fig. When replacing or reinstalling the head, ALWAYS use new gasket(s) and bolts to avoid possible coolant and/or compression leaks which could result in engine damage

  1. Apply a thin coating of pipe sealant with Teflon® to the threads of the short cylinder head bolts, nearest to the exhaust manifold. Do not apply sealant to the long bolts. Install the cylinder head bolts.
  2.  


NOTE
Always use new cylinder head bolts to ensure a leak-tight assembly. Torque retention with used bolts can vary, which may result in coolant or compression leakage at the cylinder head mating surface area.

  1. For vehicles through 1994, tighten the cylinder head attaching bolts, in sequence, to the following specifications:

    Step 1:37 ft. lbs. (50 Nm)
     
    Step 2:45 ft. lbs. (60 Nm)
     
    Step 3:52 ft. lbs. (70 Nm)
     

  2.  
  3. For vehicles through 1992, retighten the cylinder head bolts, in sequence, one at a time in the following manner:
    1. Long cylinder head bolts: Loosen the bolts and back them out 2-3 turns. Retighten to 11-18 ft. lbs. (15-25 Nm). Then tighten the bolt an additional 85-105° and go to the next bolt in sequence.
    2.  
    3. Short cylinder head bolts: Loosen the bolts and back them out 2-3 turns. Retighten to 11-18 ft. lbs. (15-25 Nm). Then tighten the bolt an additional 65-85°.
    4.  

  4.  
  5. For 1993-94 vehicles, retighten the cylinder head bolts, in sequence, one at a time in the following manner:
    1. Long cylinder head bolts: Loosen the bolts and back them out 2-3 turns. Retighten to 11-18 ft. lbs. (15-25 Nm). Then tighten the bolt an additional 85-95° and go to the next bolt in sequence.
    2.  
    3. Short cylinder head bolts: Loosen the bolt and back them out 2-3 turns. Retighten to 7-15 ft. lbs. (10-20 Nm). Then tighten the bolt an additional 85-95°.
    4.  

  6.  


NOTE
When cylinder head attaching bolts have been tightened using the above procedures, it is not necessary to retighten bolts after extended engine operation. However, bolts can be checked for tightness if desired.



Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-3.8L engine

  1. Dip each pushrod end in oil conditioner or heavy engine oil, then install the pushrods in their original position.
  2.  
  3. For each valve, rotate crankshaft until the tappet rests on the heel (base circle) of the camshaft lobe. Torque the fulcrum attaching bolts to 44 inch lbs. (5 Nm) maximum.
  4.  
  5. Lubricate all rocker arm assemblies with oil conditioner or heavy engine oil.
  6.  
  7. Tighten the fulcrum bolts a second time to 19-25 ft. lbs. (26-34 Nm). For final tightening, camshaft may be in any position.
  8.  


NOTE
If original valve train components are being installed, a valve clearance check is not required. If a component has been replaced, perform a valve clearance check.

  1. Install the exhaust manifold(s) and the lower intake manifold. For details, please see these procedures located earlier in this section.
  2.  
  3. Install the injector fuel rail assembly. Tighten the retaining bolts to 71-97 inch lbs. (8-11 Nm).
  4.  
  5. Position the rocker arm/valve cover(s) and new gasket on cylinder head and install attaching bolts. Note location of spark plug wire routing clip stud bolts. Tighten attaching bolts to 80-106 inch lbs. (9-12 Nm).
  6.  
  7. Install the upper intake manifold, then connect the ignition wires to the spark plugs.
  8.  
  9. If the left cylinder head is being installed, perform the following: install oil fill cap, compressor mounting and support brackets, power steering pump mounting and support brackets and the alternator/support bracket.
  10.  
  11. If the right cylinder head is being installed, perform the following: install the PCV valve, alternator bracket, thermactor pump and pump pulley, accessory drive idler, thermactor air control valve or air bypass valve hose.
  12.  
  13. Install the accessory drive belt. Attach the thermactor tube(s) support bracket to the rear of the cylinder head. Tighten the attaching bolts to 30-40 ft. lbs. (40-55 Nm).
  14.  
  15. Install the air cleaner assembly, including the air intake duct and heat tube.
  16.  
  17. Connect the negative battery cable and fill the cooling system.
  18.  
  19. Start the engine and check for leaks.
  20.  

4.6L Engine
FWD
  1. To remove the head on a 4.6L engine that is a front-wheel drive, it is first necessary to remove the engine from the vehicle. Since an explanation on how to remove the engine has already been given in this section and a detailed account of how to disassemble the head follows this, an abbreviated account on removal of the head is given here.
  2.  
  3. Remove the engine from the vehicle.
  4.  
  5. Remove the valve covers.
  6.  
  7. Remove the front engine covers.
  8.  
  9. Remove the intake manifold.
  10.  
  11. Remove the crankshaft position sensor pulse wheel.
  12.  
  13. Remove the rocker arms.
  14.  
  15. remove the exhaust manifolds.
  16.  
  17. Drain the engine coolant from the cylinder block.
  18.  
  19. Rotate the engine to No. 1 top dead center (TDC).
  20.  
  21. Install the camshaft position tool in the rear D-slots of the camshafts.
  22.  
  23. Remove the bolts retaining The RH and LH primary timing chain tensioners to the cylinder heads and remove the timing chain tensioners.
  24.  
  25. Remove the LH and RH primary timing chains, timing chain tensioner arms, and timing chain guides. Do not loosen the camshaft-timing sprocket retaining bolts.
  26.  
  27. Remove the outlet heater water hose retaining bolts from the rear of the RH cylinder head.
  28.  
  29. Using the reverse of the torque sequence, loosen and remove the 10 cylinder head bolts.
  30.  
  31. The cylinder head bolts are torque to yield and must be replaced. Do not re-use the old head bolts. Discard them.
  32.  
  33. Remove the heads. Remove the head gaskets.
  34.  


NOTE
The cylinder heads must not be set on the head face if the valves are open. Damage may occur to the valves.

 
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