Cylinder Head: Assembly

WARNING: This page is about a different car, the 2003 Ford Focus. However, it is still accessible from the selected car via links, so may be relevant.

Install the valve seals.

Fig 1: Installing Valve Seals
Courtesy of FORD MOTOR CO.

NOTE: If installing the original valves, make sure, that the valves are installed in the position from which they were removed. Coat the valve stems with engine oil before installation.

Fig 2: Installing Exhaust And Intake Valves

Courtesy of FORD MOTOR CO.

Install the exhaust and intake valves.
Using special tool, compress the valve spring and install the valve spring retainer.

Fig 3: Installing Valve Spring Retainer
Courtesy of FORD MOTOR CO.

NOTE: Lubricate the camshaft lobes and bearing surfaces with heavy engine oil (SG grade).

NOTE: Inspect for the presence of a clogged oil gallery. Verify that the camshaft contains the camshaft oil flow control rod and the rear end has a cup plug installed prior to the installation of the camshaft.

Fig 4: Installing Camshaft

Courtesy of FORD MOTOR CO.

Install the camshaft.
Apply a thin film of light engine oil to the lip of the camshaft front seal.

NOTE: The seal depth should be 0.05-0.0 mm below flush with the cylinder head front face.

Fig 5: Installing Camshaft Front Seal

Courtesy of FORD MOTOR CO.

Using the special tool, install the camshaft front seal.
Install the camshaft thrust plate.

Fig 6: Installing Camshaft Thrust Plate
Courtesy of FORD MOTOR CO.

CAUTION: Color codes on valve tappets must index with oil feed holes in the cylinder head.

Install the valve tappets using Hypoid oil.
1. Install the valve tappets.
2. Install the valve tappet guide plates.
3. Install the valve tappet guide retainers.
  
  Fig 7: Installing Valve Tappets
  Courtesy of FORD MOTOR CO.
Install the rocker arms.

Fig 8: Installing Rocker Arms
Courtesy of FORD MOTOR CO.
Install the coil bracket, coil and spark plug wires.

Fig 9: Installing Coil Bracket, Coil And Spark Plug Wires
Courtesy of FORD MOTOR CO.

NOTE: Inspect the water outlet connection gasket. Install a new gasket if it is cracked, torn, or damaged.

Fig 10: Installing Water Outlet Connection

Courtesy of FORD MOTOR CO.

Install the water outlet connection.

NOTE: Tighten the bolts evenly.

Install the exhaust manifold.
- Use a new gasket.
  
  Fig 11: Installing Exhaust Manifold
  Courtesy of FORD MOTOR CO.
Install a new gasket and the intake manifold.
- Tighten the nuts and bolts to 10 Nm and 90 degrees.
  
  Fig 12: Installing Intake Manifold
  Courtesy of FORD MOTOR CO.
Using the special tool. Install the camshaft timing belt pulley.

Fig 13: Installing Camshaft Timing Belt Pulley
Courtesy of FORD MOTOR CO.
Install the spark plugs (shown with engine removed).

Fig 14: Installing Spark Plugs
Courtesy of FORD MOTOR CO.

CAUTION: Use a blunt object (for example plastic cable tie) to apply the silicone grease, to avoid damaging the spark plug connector seal.

CAUTION: Push on the spark plug connector in a straight movement.

NOTE: Coat the inside of the spark plug connector with silicone grease to a depth of 5-10 mm.

Fig 15: Pushing On Spark Plug Connector

Courtesy of FORD MOTOR CO.

Push on the spark plug connector until it engages.
Install the CMP sensor.

Fig 16: Installing CMP Sensor
Courtesy of FORD MOTOR CO.