How to replace Cylinder Head on Ford Windstar?

The details to replace Cylinder head on ford windstar are as follows :----


Cylinder Head
REMOVAL & INSTALLATION Instructions are mentioned below :---

3.0L Engine

1. Rotate the crankshaft to 0 TDC on the compression stroke.
2. Remove or disconnect the following:
   
   NOTE

   The fuel injectors and fuel injection supply manifold may be removed with the lower intake manifold as an assembly.
   
   
   
   
   Negative battery cable

   Coolant

   Cowl top vent panel

   Air cleaner outlet tube from the throttle body

   All necessary vacuum lines

   EGR backpressure transducer from the EGR valve

   EGR valve tube away from the valve

   All necessary engine wiring

   Fuel system pressure

   Fuel line safety clips and disconnect the fuel lines
   
   
   
   
   Ignition wires and ignition coil pack

   Upper radiator and heater hoses

   Camshaft position sensor
3. If the front cylinder head is being removed, perform the following:
   1. Disconnect the alternator electrical harness.
   2. Rotate the tensioner clockwise and remove the accessory drive belt.
   3. Remove the automatic belt tensioner assembly.
   4. Remove the alternator.
   5. Remove the power steering mounting bracket retaining bolts. Leave the hoses connected and place the pump aside in a position to prevent fluid from leaking out.
   6. Remove the engine oil dipstick tube from the exhaust manifold.
4. If the rear cylinder head is being removed, perform the following:
   1. Remove the alternator belt tensioner bracket.
   2. Remove the heater supply tube retaining brackets from the exhaust manifold.
   3. Remove the vehicle speed sensor cable retaining bolt.
   4. Remove the EGR vacuum regulator sensor and bracket.
5. Remove or disconnect the following:
   
   NOTE

   Pushrods must be installed in their original positions. Note pushrod location during removal.
   
   
   
   
   Valve covers
   
   
   
   
   Pushrods

   Lower intake manifold

   Spark plugs

   Exhaust manifolds

   Cylinder head bolts

   Cylinder head from the engine block and discard the gaskets

To install:

1. The cylinder head should be cleaned and inspected prior to installation.
2. Lightly oil all bolt and stud bolt threads before installation.
3. Clean all gasket mating surfaces thoroughly.
4. Install or connect the following:
   
   WARNING

   Always use new cylinder head bolts when installing the cylinder head or damage to the engine may occur.
   
   
   
   NOTE

   When the cylinder head attaching bolts have been tightened using this procedure, it is not necessary to retighten the bolts after extended engine operation. The bolts can be rechecked for tightness if desired.
   
   
   
   NOTE

   The rocker arm seats must be fully seated in the cylinder head and the pushrods must be seated in the rocker arm sockets prior to the final tightening.
   
   
   
   
   New head gaskets on the cylinder block, noting the UP position mark on the gasket face and using the dowels in the engine block for alignment. If the dowels are damaged, they must be replaced.
   
   
   
   
   Cylinder head on the cylinder block. Tighten the cylinder head bolts in 2 steps following the proper torque sequence. The first step is 37 ft. lbs. (50 Nm) and the second step is 68 ft. lbs. (92 Nm).
   
   

   

   

   Fig. Cylinder head bolt torque sequence-3.0L engine
   
   
   
   
   Intake manifold

   All engine wiring harnesses previously disconnected

   Pushrods. Dip each end in engine assembly lubricant.

   Rocker arms, seats and retaining bolts. Lubricate all rocker arm components with engine assembly lubricant. Tighten the bolts to 62-132 inch lbs. (7-15 Nm).
   
   
   
   
   Final tighten all rocker arm retaining bolts to 20-28 ft. lbs. (26-38 Nm)

   Exhaust manifolds

   Spark plugs

   Valve covers
5. If the rear cylinder head is being installed, perform the following:
   1. Install the EGR vacuum regulator sensor and bracket.
   2. Install the vehicle speed sensor cable retaining bolt.
   3. Install the heater supply tube retaining brackets from the exhaust manifold.
   4. Install the alternator belt tensioner bracket.
   5. Install the engine oil dipstick tube from the exhaust manifold.
6. If the front cylinder head is being installed, perform the following:
   1. Install the power steering mounting bracket retaining bolts. Leave the hoses connected and place the pump aside in a position to prevent fluid from leaking out.
   2. Install the alternator.
   3. Install the automatic belt tensioner assembly.
   4. Rotate the tensioner clockwise and install the accessory drive belt.
   5. Connect the alternator electrical harness.
7. Install or connect the following:
   
   
   Camshaft position sensor

   Upper radiator and heater hoses

   Ignition coil pack and spark plug wires

   Fuel lines and fuel line safety clips

   EGR valve tube

   EGR backpressure transducer

   All necessary vacuum lines

   Air cleaner outlet tube to the throttle body

   Cowl top vent panel
8. Fill and bleed the cooling system.
   
   NOTE

   Engine coolant is corrosive to engine bearing material. Replace the engine oil after removal of any coolant-carrying component to help prevent potential bearing damage.
9. Change the engine oil and filter
10. Connect the negative battery cable.
11. Start the engine and check for leaks.

3.8L Engine

1. Remove or disconnect the following:
   
   
   Negative battery cable

   Coolant

   Air cleaner assembly

   Cowl top vent panel

   Accessory drive belt
2. If the front cylinder head is being removed, perform the following:
   1. Remove the oil filler cap.
   2. Remove the air conditioning compressor mounting bracket and set the air conditioning compressor aside with the refrigerant lines still connected.
   3. Remove the power steering pump and bracket. Leave the power steering hoses connected and place the pump aside in the engine compartment.
   4. Remove the alternator and mounting bracket.
3. If the rear cylinder head is being removed, perform the following:
   1. Remove the accessory drive belt tensioner.
   2. Remove the PCV valve.
   3. Remove the power steering line bracket.
   4. Remove the tensioner bracket.
   5. Remove the coil pack assembly.
4. Remove or disconnect the following:
   
   NOTE

   Pushrods must be installed in their original positions. Note pushrod location during removal.
   
   
   
   
   Upper intake manifold

   Valve cover

   Fuel system pressure

   Fuel charging assembly

   Lower intake manifold

   Exhaust manifolds
   
   
   
   
   Pushrods

   Cylinder head bolts

   Cylinder head from the engine block and discard the gaskets

To install:

1. The cylinder head should be cleaned and inspected prior to installation.
2. Lightly oil all bolt and stud bolt threads before installation.
3. Clean all gasket mating surfaces thoroughly.
4. Position new head gaskets on the cylinder block, noting the UP position mark on the gasket face, using the dowels in the engine block for alignment. If the dowels are damaged, they must be replaced. 
   
   WARNING

   Always use new cylinder head bolts when installing cylinder head or damage to the engine may occur.
5. Position the cylinder head on the cylinder block.
6. Lubricate the cylinder head bolts with engine oil and install. Tighten the cylinder head bolts following the proper torque sequence as follows:
   
   NOTE

   Do not loosen all of the cylinder head bolts at once. Only work on 1 bolt at a time or damage to the engine may occur.
   
   
   
   
   Step 1: 15 ft. lbs. (20 Nm)

   Step 2: 29 ft. lbs. (40 Nm)

   Step 3: 37 ft. lbs. (50 Nm)
   
   

   

   

   Fig. Cylinder head bolt torque sequence-3.8L engine

In sequence, loosen each cylinder head bolt 2-3 turns and retighten in 2 steps.

Long bolts, step 1: 29-37 ft. lbs. (40-50 Nm); step 2: tighten an additional 175-185 degrees.

Short bolts, step 1: 15-22 ft. lbs. (20-30 Nm); second 2: tighten an additional 175-185 degrees.

1. Dip each pushrod end in engine assembly lubricant. Install the pushrods in their original positions.
2. Lubricate all rocker arm components with engine assembly lubricant.
3. For the rocker arm being installed, rotate the engine clockwise until the valve tappet rests on the heel (base circle) of the camshaft lobe.
4. Install the rocker arms, seats and bolts and tighten to 44 inch lbs. (5 Nm).
5. Perform the previous 2 steps for each rocker arm.
6. After all rocker arms have been installed, final tighten all bolts to 22-29 ft. lbs. (30-40 Nm).
7. Install or connect the following:
   
   
   Exhaust manifolds

   Lower intake manifold

   Fuel injection charging assembly

   Valve covers with new gaskets. Tighten the bolts to 71-97 inch lbs. (8-11 Nm).

   Upper intake manifold

   Spark plugs and ignition wires
8. If the front cylinder head is being installed, perform the following:
   1. Install the alternator and mounting bracket.
   2. Install the power steering pump and bracket.
   3. Install the air conditioning compressor bracket.
   4. Install the oil filler cap.
9. If the rear cylinder head is being installed, perform the following:
   1. Install the coil pack assembly.
   2. Install the tensioner bracket.
   3. Install the power steering line bracket.
   4. Install the PCV valve.
   5. Install the accessory drive belt tensioner.
   6. Rotate the tensioner clockwise and install the accessory drive belt.
10. Install the cowl top vent panel.
11. Install the air cleaner assembly.
12. Fill and bleed the cooling system.
13. Connect the negative battery cable.

This will help.Thanks.

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Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html