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Cylinder Head: Installation

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.
    CAUTION: Do not use abrasive grinding disk to remove gasket material; use only plastic scrapers. Do not scratch or gouge aluminum sealing surfaces.
  1. Clean all gasket material from the mating surfaces on the cylinder head and cylinder block. Clean out the bolt holes in the cylinder block. Inspect the cylinder head for distortion. for additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  2. Install a new head gasket on the cylinder block.
    3. CAUTION: Always install new cylinder head bolts.
    NOTE: Lubricate the cylinder head bolts with engine oil prior to installation.
  3. Install the cylinder head assembly and tighten the cylinder head bolts in the following sequence.
    1. Tighten all bolts in a single sequence to 50 Nm.
    2. Back the bolts off 1/2 turn.
    3. Tighten the bolts in sequence shown to 50 Nm.
    4. Rotate all the bolts in a single sequence an additional 180 degrees in two steps of 90 degrees each.
      Fig 1: Identifying Cylinder Head Bolts Tightening Sequence
      G01615149Courtesy of FORD MOTOR CO.
  4. Install the valve cover.
    Fig 2: Installing Valve Cover
    G01615150Courtesy of FORD MOTOR CO.
  5. Connect the fresh air and PCV hoses.
    • Make sure that the twist-on PCV is secure.
      Fig 3: Connecting Fresh Air And PCV Hoses
      G01615151Courtesy of FORD MOTOR CO.
  6. Connect the crankshaft position sensor (CKP) electrical connector.
    Fig 4: Connecting Crankshaft Position Sensor Electrical Connector
    G01615152Courtesy of FORD MOTOR CO.
  7. Install and tension the timing belt. For additional information, refer to TIMING BELT .
  8. Install the catalytic converter to the exhaust manifold.
    Fig 5: Installing Catalytic Converter To Exhaust Manifold
    G01615153Courtesy of FORD MOTOR CO.
  9. Install the heat shield.
    1. Heat shield
    2. Power steering tube
      Fig 6: Installing Heat Shield
      G01615154Courtesy of FORD MOTOR CO.
  10. Raise and support the vehicle. For additional information, refer to JACKING & HOISTING .
  11. Connect the knock sensor (KS) and the oil pressure switch electrical connector.
    Fig 7: Connecting Knock Sensor And Oil Pressure Switch Electrical Connector
    G01615155Courtesy of FORD MOTOR CO.
  12. Connect the CMS sensor electrical connector.
    Fig 8: Connecting CMS Sensor Electrical Connector
    G01615156Courtesy of FORD MOTOR CO.
  13. Install the intake manifold bracket (shown with engine removed).
    1. Install the bolts and tighten the nuts.
      Fig 9: Installing Intake Manifold Bracket
      G01615157Courtesy of FORD MOTOR CO.
  14. Lower the vehicle.
  15. Install the fuel hose.
    Fig 10: Installing Fuel Hose
    G01615158Courtesy of FORD MOTOR CO.
  16. Install the coolant hose.
    Fig 11: Installing Coolant Hose
    G01615159Courtesy of FORD MOTOR CO.
  17. Install the coolant hoses to the thermostat housing.
    Fig 12: Installing Coolant Hoses To Thermostat Housing
    G01615160Courtesy of FORD MOTOR CO.
  18. Install the oil level indicator tube.
    Fig 13: Installing Oil Level Indicator Tube
    G01615161Courtesy of FORD MOTOR CO.
  19. Install the vacuum hose.
    Fig 14: Installing Vacuum Hose
    G01615162Courtesy of FORD MOTOR CO.
  20. Install the vacuum hoses.
    1. EVAP
    2. Brake servo
    3. Delta Pressure Feedback Electronic System Sensor (DPFE)
    4. EGR-valve
      Fig 15: Installing EVAP, Brake Servo, DPFE And EGR-Valve Vacuum Hoses
      G01615163Courtesy of FORD MOTOR CO.
  21. Connect the HO2S electrical connector.
    Fig 16: Connecting HO2S Electrical Connector
    G01615164Courtesy of FORD MOTOR CO.
  22. Connect both PCM connectors.
    Fig 17: Connecting PCM Connectors
    G01615165Courtesy of FORD MOTOR CO.
  23. Install the speed control cable.
    1. Install the cable.
    2. Install the plastic clip.
      Fig 18: Installing Speed Control Cable
      G01615166Courtesy of FORD MOTOR CO.
  24. Install the accelerator cable.
    1. Install the cable.
    2. Install the plastic clip.
      Fig 19: Installing Accelerator Cable
      G01615167Courtesy of FORD MOTOR CO.
  25. Install the air cleaner housing.
    1. Connect the MAF electrical connector.
    2. Attach the intake hose.
    • Install the air cleaner housing to the rubber bushing.
      Fig 20: Installing Air Cleaner Housing
      G01615168Courtesy of FORD MOTOR CO.
  26. Change the engine oil (and the oil filter).
  27. Fill the cooling system. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  28. Connect the battery ground cable.
    29. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.
  29. Install the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  30. Start the engine and check for leaks.
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