FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
Courtesy of Operation CHARM: Car repair manuals for everyone.
Home >> Mercury >> 1997 >> Cougar/XR7 V8-4.6L VIN W >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Cylinder Head Assembly >> Service and Repair >> Removal and Installation >> Removal

Removal

1. Disconnect battery ground cable (14301).
2. Drain cooling system and remove fan blade (8600) and fan shroud (8146).
3. Relieve fuel system pressure and disconnect fuel lines.
4. Remove air cleaner outlet tube (9B659).
5. Remove windshield wiper governor (17C476).
6. Release drive belt tensioner (6B209) and remove drive belt (8620).

CAUTION: Do not pull on ignition wire as wires may separate from the connector in the ignition wire boot.

7. Disconnect ignition wires from spark plugs (12405).
8. Disconnect ignition wires and ignition wire separators (12297) from valve cover stud bolts.
9. Disconnect fuel charging wiring (9D930) from both ignition coils (12029) and camshaft position sensor (CMP sensor)(6B288).
10. Remove bolts retaining power steering oil reservoir (3A697) to the LH ignition cold bracket and position out of the way.
11. Remove three nuts retaining RH ignition coil bracket to engine front cover (6019).
12. Remove LH ignition coil and ignition wires as an assembly.
13. Remove four nuts retaining LH ignition coil bracket to engine front cover.
14. Slide ignition coil brackets and ignition wire and bracket (12280) assembly off mounting studs and remove from vehicle.
15. Remove water pump pulley (8509).
16. Disconnect generator wiring harness from junction block, front fender apron (16054) and generator (GEN)(10346).
17. Remove two bolts retaining generator mounting bracket (10153) to intake manifold (9424).
18. Remove two bolts retaining generator to cylinder blocks (6010) and remove generator (GEN)(10300).
19. Disconnect and remove positive crankcase ventilation valve (PCV valve)(6A666) from valve cover (6582).
20. Disconnect 42-pin engine harness connector and 8-pin connector leading to the mass air flow sensor (MAP sensor)(12B579).
21. Remove nut retaining A/C line to the RH front fender apron.
22. Lift A/C line and feed the fuel charging wiring 42-pin connector under the A/C line. Position fuel charging wiring out of the way.
23. Disconnect the fuel charging wiring from the crankshaft position sensor (CKP sensor)(6C315), A/C clutch (2884) and evaporative emission canister purge valves (EVAP canister purge valve)(9C915).
24. Raise vehicle on hoist.
25. Remove bolts retaining power steering pump to cylinder blocks and engine front cover.

NOTE: The front lower bolt on the power steering pump (3A674) will not come all the way out.

26. Secure the power steering pump out of the way.
27. Remove oil pan (6675) and oil pan gasket (6710).
28. Remove crankshaft pulley bolt (6A340) and crankshaft pulley retaining washer (6378) from crankshaft (6303).





29. Install Crankshaft Damper Remover T58P-6316-D on crankshaft pulley (6312) and pull crankshaft pulley from crankshaft.
30. Disconnect the fuel charging wiring from the electronic variable orifice sensor and oil pressure sensor (9278).
31. Position fuel charging wiring out of the way.
32. Disconnect EGR valve to exhaust manifold tube (9D477) from RH exhaust manifold (9430).
33. Disconnect three way catalytic converter (TWC)(5E212) from RH and LH exhaust manifolds.

Securing Catalytic Converter To Crossmember:





34. Lower exhaust system and secure to crossmember in positions shown with wire.
35. Remove bolt retaining starter wiring harness to rear of RH cylinder head (6049).
36. Lower vehicle.
37. Remove bolts and stud bolts retaining RH valve cover to cylinder head and remove valve cover.
38. Disconnect accelerator cable (9A758) and speed control actuator cable (9A825).
39. Remove accelerator cable bracket (9723) from intake manifold and position out of the way.
40. Remove bolts and stud bolts retaining LH valve cover to cylinder head and remove valve cover.
41. Disconnect vacuum hose from throttle body adapter vacuum port.
42. Disconnect fuel charging wiring from heated oxygen sensors (HO2S)(9F472).
43. Disconnect heater water hose (18472).
44. Remove two bolts retaining water hose connection (8592) to intake manifold and position upper radiator hose (8260) and water hose connection out of the way.

NOTE: Two water outlet connection retaining bolts also retain intake manifold.





45. Remove the remaining nine bolts retaining intake manifold to cylinder heads and remove intake manifold.
46. Remove intake manifold gaskets (9461).





47. Remove eight stud bolts and seven bolts retaining engine front cover to engine. Remove engine from cover.
48. Remove timing chains.
49. Remove 10 bolts retaining LH cylinder head to cylinder blocks.

NOTE: The lower rear bolt cannot be removed due to interference with the power brake booster (2005). Use a rubber band or similar item to hold bolt away from cylinder block.

50. Remove LH cylinder head.

NOTE: Cylinder head must not be set on head face. If valves are open damage may occur.





51. Remove stud bolts retaining heater water hose to RH cylinder head.
52. Remove 10 bolts retaining RH cylinder head to cylinder blocks.





NOTE: The lower rear bolt cannot be removed due to interference with the A/C evaporator housing (19850). Use a rubber band or similar item to hold bolt away from cylinder blocks as shown in the illustration.

53. Remove RH cylinder head.
54. If cylinder heads are to be replaced or serviced, refer to Cylinder Head Disassembly and Assembly.


pro multis Credits:Operation CHARM About Operation CHARM