You will need: all the tools necessary to remove the battery, cylinder head cover, timing belt, camshafts.
1. Reduce the pressure in the fuel system (see Reducing pressure in the engine fuel system).
2. Remove the battery (see Removing and installing the battery).
3. Drain the fluid from the engine cooling system (see Replacing the coolant).
4. Disconnect the cooling system hoses and pipes and disconnect the coolant temperature sensor.
5. Disconnect the wiring harness connector from the throttle body cover.
6. Remove the air supply hose and air filter (see Removing and installing the air filter and intake silencer).
7. Disconnect the hoses from the oil cooler.
8. Disconnect the turbocharger from the cylinder head.
9. Remove the crankcase ventilation system pipe.
10. Disconnect the wiring harness connector from the ignition coil.
11. Disconnect the fuel supply line.
12. Disconnect the electrical connectors of the injectors.
13. Remove the timing belt (see Replacing the timing belt of the 2.5L Duratec-V15 engine).
14. Remove the cylinder head cover (see Replacing camshafts and cylinder head cover seals for duratec-v15 2.5l engine).
15. Remove the camshafts (see Replacing camshafts and cylinder head cover seals for duratec-v15 2.5l engine).
16. Remove the catalytic converter (see Removing and installing the catalytic converter and replacing its gasket).
17. Loosen the twelve cylinder head mounting bolts in the order shown in Fig. 5.45, then completely unscrew the head mounting bolts and remove them together with the washers.
WARNING: The cylinder head bolts may only be removed when the engine is cold.
18. Remove the cylinder head.
USEFUL TIP: It is easier to remove the cylinder head with an assistant, as it is quite heavy.
19. Clean the mating surfaces of the head and block.
20. Check the cylinder head for warpage. To do this, place a ruler on the surface of the head, first in the middle along, then across and diagonally, and measure the gap between the surface of the head and the ruler with a feeler gauge. Replace the cylinder head if the gap is more than 0.1 mm.
21. Install the gasket and then the cylinder head in the reverse order of removal, taking into account the following: – remove any oil or coolant from the threaded holes of the cylinder head mounting bolts that got there when removing the head; – be sure to install a new cylinder head gasket, reusing it is not allowed; – lubricate the bolts with engine oil; – tighten the bolts on a cold engine in the reverse order to that shown in Fig. 5.45, in three stages: 1st – with a torque of 20 N·m (2 kgf·m); 2nd – torque 60 Nm (6 kgf·m); 3rd – tighten to an angle of 130°.
22. Install all removed parts and assemblies in the reverse order of removal. After installing the camshafts and timing belt, check and, if necessary, adjust the valve clearances (see Adjusting valve clearances).
23. Adjust the timing belt tension (see Replacing the timing belt of the 2.5L Duratec-V15 engine).
24. Fill the engine cooling system with coolant (see Replacing the coolant).
Fig. 5.45. Procedure for loosening the cylinder head mounting bolts.
(This article is a copy from the website: www.fordbook.ru)