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HOMESERVICE MANUALSFORD2009FUSION SEL, 3.0 1, FWDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 256 (ENGINE SYSTEM)REMOVALCYLINDER HEAD
2009 Ford Fusion SEL, 3.0 1, FWD

Cylinder Head

2009 Ford Fusion SEL, 3.0 1, FWDSECTION Cylinder Head
WARNING: This page is about a different car, the 2006 Mercury Grand Marquis and 2006 Ford Crown Victoria. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL(S) DESCRIPTION

G04583583
 Remover, Crankshaft Vibration Damper
303-009 (T58P-6316-D)
G04583584
 Remover, Crankshaft Front Oil Seal
303-107 (T74P-6700-A)
G04583585
 Engine Lifting Bracket Set
303-DS086 (D93P-6001-A)
G04583586
 Compressor, Valve Spring
303-567 (T97P-6565-AH)
G04583587
 Spacer, Valve Spring Compressor
303-382 (T91P-6565-AH)
G04583588
 Remover/Installer, Cylinder Head
303-572 (T97T-6000-A)
MATERIAL SPECIFICATIONS

Item Specification
Silicone Gasket Remover ZC-30 -
Motorcraft Metal Surface Prep ZC-31 -

    Cylinder heads 

    WARNING: If equipped with fire suppression system, depower the system. For important safety warnings and procedures, refer to FIRE SUPPRESSION SYSTEM .
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Remove the engine. For additional information, refer to ENGINE  in the Removal portion of this article.
  3. Remove the bolts and the flexplate.
    Fig 1: Locating Flexplate Bolts
    G03885612Courtesy of FORD MOTOR CO.
  4. Remove the engine/transmission spacer plate.
    Fig 2: Removing Engine/Transmission Spacer Plate
    G04583590Courtesy of FORD MOTOR CO.
  5. Mount the engine on a suitable engine stand.
    Fig 3: Mounting Engine On Suitable Engine Stand
    G04583591Courtesy of FORD MOTOR CO.
  6. Remove the LH and the RH lifting brackets.
    Fig 4: Removing LH And RH Lifting Brackets
    G04583592Courtesy of FORD MOTOR CO.
  7. Remove the bolts and the RH engine mount.
    Fig 5: Removing RH Engine Mount
    G04583593Courtesy of FORD MOTOR CO.
    8. NOTE: LH shown, RH similar.
  8. Remove the drain plugs from the engine block. Allow the coolant to completely drain.
    • Install the drain plugs when finished.
    • To install, tighten to 20 Nm (15 lb-ft).
      Fig 6: Removing Drain Plugs From Engine Block
      G04583594Courtesy of FORD MOTOR CO.
  9. Remove the bolt and the battery cables from the engine.
    Fig 7: Removing Bolt And Battery Cables From Engine
    G04583595Courtesy of FORD MOTOR CO.
  10. Disconnect the exhaust gas recirculation (EGR) tube from the exhaust manifold.
    Fig 8: Disconnecting Exhaust Gas Recirculation (EGR) Tube From Exhaust Manifold
    G04583596Courtesy of FORD MOTOR CO.
  11. Disconnect the 8 ignition coil electrical connectors.
    Fig 9: Disconnecting Eight Ignition Coil Electrical Connectors
    G04583597Courtesy of FORD MOTOR CO.
  12. Disconnect the 8 fuel injector electrical connectors.
    Fig 10: Disconnecting Eight Fuel Injector Electrical Connectors
    G04583598Courtesy of FORD MOTOR CO.
  13. Remove the bolts and the intake manifold shield.
    Fig 11: Removing Bolts And Intake Manifold Shield
    G04583599Courtesy of FORD MOTOR CO.
  14. Remove the crankcase ventilation tube.
    Fig 12: Removing Crankcase Ventilation Tube
    G04583600Courtesy of FORD MOTOR CO.
  15. Remove the generator mounting bracket.
    • Remove the bolts.
    • Remove the bracket.
      Fig 13: Removing Generator Mounting Bracket
      G04583601Courtesy of FORD MOTOR CO.
  16. Disconnect the throttle control and the throttle position (TP) sensor electrical connectors.
    Fig 14: Locating Throttle Control And Throttle Position (TP) Sensor Electrical Connectors
    G03881492Courtesy of FORD MOTOR CO.
  17. Disconnect the generator electrical connector.
    Fig 15: Disconnecting Generator Electrical Connector
    G04583603Courtesy of FORD MOTOR CO.
  18. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
    Fig 16: Disconnecting Cylinder Head Temperature (CHT) Sensor Electrical Connector
    G04583604Courtesy of FORD MOTOR CO.
  19. Remove the generator wiring harness anchor from the LH front stud.
    Fig 17: Removing Generator Wiring Harness Anchor From LH Front Stud
    G04583605Courtesy of FORD MOTOR CO.
  20. Disconnect the ground wire from the RH rear stud.
    Fig 18: Disconnecting Ground Wire From RH Rear Stud
    G04583606Courtesy of FORD MOTOR CO.
  21. Disconnect the camshaft position (CMP) sensor electrical connector.
    Fig 19: Disconnecting Camshaft Position (CMP) Sensor Electrical Connector
    G04583607Courtesy of FORD MOTOR CO.
  22. Disconnect the radio ignition interference capacitor and remove the engine control sensor wiring.
    Fig 20: Removing Engine Control Sensor Wiring
    G04583608Courtesy of FORD MOTOR CO.
  23. Disconnect the fuel charging wiring from the crash bracket and the wiring support bracket and remove the harness from the engine.
    Fig 21: Removing Harness From Engine Assembly
    G04583609Courtesy of FORD MOTOR CO.
  24. Disconnect the EGR tube nut from the EGR system module.
    Fig 22: Disconnecting EGR Tube Nut From EGR System Module
    G04583610Courtesy of FORD MOTOR CO.
  25. Remove the generator.
    1. Remove the bolts.
    2. Remove the generator.
      Fig 23: Removing Generator And Bolts
      G04583611Courtesy of FORD MOTOR CO.
  26. Remove the intake manifold crash bracket bolt and prevent the bolt from contacting the cylinder head with a rubber band or tie strap.
    Fig 24: Removing Crash Bracket Bolt
    G04583612Courtesy of FORD MOTOR CO.
  27. Remove the intake manifold crash bracket stud bolt.
    Fig 25: Removing Intake Manifold Crash Bracket Stud Bolt
    G04583613Courtesy of FORD MOTOR CO.
  28. Remove the 8 bolts and the 8 ignition coils.
    Fig 26: Removing Bolts And Ignition Coils
    G04583614Courtesy of FORD MOTOR CO.
  29. Remove the 2 bolts and the coolant outlet adapter.
    Fig 27: Removing Bolts And Coolant Outlet Adapter
    G04583615Courtesy of FORD MOTOR CO.
  30. Remove the thermostat.
    Fig 28: Removing Thermostat
    G04583616Courtesy of FORD MOTOR CO.
  31. Remove the bolts and the intake manifold.
    Fig 29: Removing Bolts And Intake Manifold
    G04583617Courtesy of FORD MOTOR CO.
  32. Remove the intake manifold gaskets and discard.
    Fig 30: Removing Intake Manifold Gaskets
    G04583618Courtesy of FORD MOTOR CO.
    33. CAUTION: 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 which make leak paths.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.