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 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.

Clean the cylinder head gasket surfaces with metal surface cleaner.
Apply silicone gasket and sealant to the locations shown.

Fig 1: Applying Silicone Gasket And Sealant To Locations Shown
Courtesy of FORD MOTOR CO.
Install a new head gasket.

Fig 2: Installing Head Gasket
Courtesy of FORD MOTOR CO.

NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.

NOTE: Lubricate the cylinder head bolts with clean engine oil.

Install the cylinder head and new bolts. Tighten the bolts in the sequence shown in five stages.
- Stage 1: Tighten the bolts to 5 Nm (44 lb-in).
- Stage 2: Tighten the bolts to 15 Nm (11 lb-ft).
- Stage 3: Tighten the bolts to 45 Nm (33 lb-ft).
- Stage 4: Turn the bolts 90 degrees.
- Stage 5: Turn the bolts an additional 90 degrees.
  
  Fig 3: Cylinder Head Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Connect the radio interference capacitor electrical connector.

Fig 4: Connecting Radio Interference Capacitor Electrical Connector
Courtesy of FORD MOTOR CO.
Install the EGR coolant hose.

Fig 5: Installing EGR Coolant Hose
Courtesy of FORD MOTOR CO.
Install the coolant bypass.
1. Install the coolant bypass and the bolts.
2. Install the coolant bypass lower hose.
  
  Fig 6: Installing Coolant Bypass
  Courtesy of FORD MOTOR CO.
Install the coolant hoses onto the coolant bypass.

Fig 7: Installing Coolant Hoses Onto Coolant Bypass
Courtesy of FORD MOTOR CO.
Connect the EGR valve electrical connector.

Fig 8: Connecting EGR Valve Electrical Connector
Courtesy of FORD MOTOR CO.
Install the air control valve hoses.

Fig 9: Installing Air Control Valve Hoses
Courtesy of FORD MOTOR CO.
Connect the EGR vacuum regulator electrical connector.

Fig 10: Connecting EGR Vacuum Regulator Electrical Connector
Courtesy of FORD MOTOR CO.
Install the fuel injector supply manifold spacers.

Fig 11: Installing Fuel Injector Supply Manifold Spacers
Courtesy of FORD MOTOR CO.
Install the intake manifold. For additional information, refer to INTAKE MANIFOLD .
Install the fuel injector supply manifold. For additional information, refer to REMOVAL & INSTALLATION .
Install the catalytic converter. For additional information, refer to EXHAUST SYSTEM .
Install the camshafts. For additional information, refer to CAMSHAFTS .
Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING .