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Home >> Mercury >> 1995 >> Mystique V6-153 2.5L DOHC >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Cylinder Head Assembly >> Service and Repair >> Removal and Installation

Removal and Installation

REMOVAL
1. Drain engine coolant from radiator (8005) and cylinder block drain plugs.
2. Remove upper intake manifold (9424) and lower intake manifold.
3. Remove oil pan (6675).
4. Remove generator (GEN) (10300) and generator mounting bracket (10153).
5. Remove heated oxygen sensor (H02S) (9F472) from RH exhaust manifold (9430).
6. If removing the LH cylinder head (6049), remove LH exhaust manifold and water pump (8501).
7. Remove engine front cover (6019).
8. Remove camshafts (6250) and valve tappets (6500).
9. Install upper front engine support insulator (6038) and front engine support bracket (6028) to front of engine and RH front fender apron (16054).
10. Remove Three Bar Engine Support D88L-6000-A or equivalent.
11. If the RH cylinder head is being removed, perform the following:
- Disconnect hoses from EGR backpressure transducer at EGR valve to exhaust manifold tube (9D477).
- Disconnect electrical connector to EGR backpressure transducer.
- Disconnect interior vacuum source hose from main emission vacuum harness.
- Disconnect fuel vapor hose from positive crankcase ventilation valve (PCV valve) (6A666).
- Disconnect electrical connector to EGR vacuum regulator solenoid.
- Remove EGR valve to exhaust manifold tube from RH exhaust manifold and remove from vehicle.
- Remove retaining bracket for fuel charging wiring (9D930) from EGR backpressure transducer bracket.
12. Remove engine air cleaner (ACL) (9600).
13. Remove crankcase ventilation tube (6758) from water bypass and oil separator (6B673).
14. Remove water bypass retaining bolt and stud bolt from RH cylinder head. Remove and position water bypass out of way.
15. If the LH cylinder head is being removed, remove the oil level dipstick (6750).





16. Remove cylinder head retaining bolts in removal sequence shown

NOTE: Remove RH cylinder head with exhaust manifold and EGR backpressure transducer bracket attached.





17. Remove the cylinder heads.
18. If required, remove exhaust manifold and EGR backpressure transducer bracket from RH cylinder head.
19. Inspect cylinder heads and cylinder block (6010). Replace components as required.

INSTALLATION
1. Clean the cylinder heads, lower intake manifold, valve cover (6582) and cylinder head gasket surfaces. If the cylinder heads were removed for a cylinder head gasket replacement, check the flatness of the cylinder heads and cylinder block gasket surfaces.
2. If removed, install exhaust manifold and EGR backpressure transducer bracket onto RH cylinder head.
3. Install the new head gaskets (6051) on the cylinder block. The head gaskets must be installed over the cylinder head to block dowels (6A008).

CAUTION: Use care when positioning cylinder heads. Damage to cylinder block and/or cylinder heads may result.

NOTE: Make sure cylinder heads are installed in their original positions.

4. Install cylinder heads onto cylinder block over cylinder head to block dowels.

CAUTION: Cylinder head retaining bolts must be replaced with new bolts. They are torque-to-yield designed and cannot be reused or damage to engine may occur.





5. Install new torque-to-yield cylinder head retaining bolts and tighten in sequence shown as follows:
- Tighten bolts to 37-43 Nm (27-32 ft. lbs.).
- Rotate bolts 85-95°.
- Loosen bolts a minimum of one full turn (360°).
- Tighten bolts to 37-43 Nm (27-32 ft. lbs.).
- Rotate bolts 85-95°.
- Rotate bolts an additional 85-95°.
6. Inspect water bypass O-rings for wear or damage. Replace O-rings as required.





7. Lubricate water bypass O-rings with Premium Cooling System Fluid E2FZ-19549-AA or-B (In Canada, Motorcraft CXC-8-B) or equivalent meeting Ford specification ESE-M97B44-A. Install water crossover to cylinder heads. Tighten bolts to 8-12 Nm (71-106 inch lbs.).





8. Install crankcase ventilation tube. Tighten retaining nut to 5-7 Nm (44-62 inch lbs.).
9. If LH cylinder head was removed, install oil level dipstick.
10. Install engine air cleaner.
11. If the RH cylinder head was removed, perform the following:
- Install retaining bracket for fuel charging wiring onto EGR backpressure transducer bracket.
- Install EGR valve to exhaust manifold tube onto RH exhaust manifold.
- Connect electrical connector to EGR backpressure transducer and EGR vacuum regulator solenoid.
- Connect fuel vapor hose to the positive crankcase ventilation valve and interior vacuum source hoses onto the main emission vacuum harness.
- Install hoses from EGR backpressure transducer onto EGR valve to exhaust manifold tube.
12. Install camshafts and valve tappets.





13. Install Three Bar Engine Support D88L-6000-A or equivalent onto engine lifting eye (17A084).
14. Install engine front cover.
15. If the LH cylinder head was removed, install the LH exhaust manifold and water pump.
16. if the RH cylinder head was removed, install the heated oxygen sensor into the RH exhaust manifold.
17. Install the generator and generator mounting bracket.
18. Install oil pan.
19. Install lower intake manifold and upper intake manifold.
20. Replace oil bypass filter (6714).
21. Fill crankcase with the proper quantity of Super Premium Motor Oil XO-5W30-QSP or equivalent meeting Ford specification ESE-M2C153-E.
22. Fill engine cooling system.
23. Run engine and check for oil and coolant leaks.
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