This article will show you how to remove and install the head while performing a headgasket job for the 2.3L 4-cylinder motor [example vehicle is a 1994 XLT 2.3L i4]. There are a few minor differences between the 2.3L and the 2.5L such as spark configuration (unless you have dual-packs) and I'm sure a different torque setting or two and minor part differences exist. Please refer to an appropriate shop manual for all of your torque ratings. Neither I, nor www.rangerforum.net or any affiliated users of said forum, claim any responsibility for work done to your or anybody elses vehicle. This is simply a helping guide to complete the job. If you don't know what you're doing or aren't comfortable with these procedures, seek professional help. As I progress through this project I will be posting new pictures daily and including my write-up. My personal reason for a head-gasket job is oil in the coolant - praying to god that my head/block isn't cracked or warped. - You should ALWAYS have your head checked for flatness and machined accordingly at a professional machine shop before re-installation of the head onto the block. Failure to do so can result in a poor seal between the headgasket and block/head. (this can and will cause leaks, making you do this whole job over again) Tools [that I know of so far]: Code: Pliers Long flat-head screwdriver Medium flat-head screwdriver Phillips head screw driver 5.5mm socket 7mm socket 5/32 socket 17mm socket 8mm deep socket 10mm deep socket (very important) 11mm deep socket 13mm deep socket 16mm deep socket 22mm deep socket BREAKER BAR 10mm open end wrench 13mm open end wrench 13mm ratcheting wrench 25-250 in-lb torque wrench 10-150 ft-lb torque wrench Extensions Swivel socket Bolt-on harmonic dampener puller Spring lock coupling tool (1/2" and 3/4") Feeler gauges Flat-edge for checking head and block As far as the parts list goes, depending on why you are doing your head-gasket job, you may need to flush your coolant system. In this case, I picked up a flush-kit from my local parts store as well as coolant system cleaner from Prestone. Parts list: Code: Felpro head gasket set Head bolts Water pump Water pump gasket Timing belt Timing belt tensioner Thermostat Upper radiator hose Lower radiator hose MotorCraft Platinum plugs Spark wires Oil + filter Coolant Coolant temperature sensor 60+ fluid ounces of carb cleaner Red RTV gasket maker (high temp made for water pumps!) ___________________ ~$355.00 1. Remove negative cable from battery post, Remove positive cable from battery post 2. Remove battery hold-down 3. Remove battery from vehicle and store in an appropriate place. 4. Remove two flat-head screws from air-box. 5. Remove and label both vacuum lines attached to air-box cover 6. Remove clamp from throttle body holding the air-box tube in place 7. Remove top portion of air-box and set aside. 8. Remove bracket from #4 exhaust cylinder (13mm socket) 9. Unplug all spark plug wires (FROM ENGINE SIDE ONLY), label the wires driver or passenger side, depending on which coil they are attached to. 10. Unplug connectors from coil packs 11. Remove both coil packs (7mm socket [I believe]) with wires attached and place them somewhere dry. 12. Remove the coil pack bracket (13mm I think) 13. Remove throttle cable and cruise cable linkage from throttle body arm (this just pops off - you might want to lightly pry on the clip inside with a flat-head) 14. Remove two throttle cable bracket bolts (10mm) 15. Disconnect all wiring from the throttle body and remove the four (10mm) bolts that hold the throttle body to the upper intake manifold. Remove throttle body from vehicle. 16. Remove bolts holding the upper intake manifold (10mm - make sure you have a deep socket for this one) 17. Remove the bolts attaching the EGR to the upper intake manifold (10mm) 18. Remove all vac lines from intake and label accordingly. 19. Disconnect fuel injector wiring (this might be a good time to measure the resistance of each injector, or once you get the lower intake off the vehicle - personal preference really) 20. Remove upper and lower radiator hoses (flat-head) and remove the two radiator mounting bolts (10mm) - Remove radiator and flush with garden hose. - I also removed the front grill and chrome trim to make the job easier later on. This only requires removing the Phillips trim screws, then the screws holding on the front grill.