Cylinder Head: Installation
- Clean all the gasket material from the mating surfaces on the cylinder head and the cylinder block. Clean out the bolt holes in the cylinder block. Inspect the cylinder head for flatness. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
- Install a new head gasket.
- Install the cylinder head and tighten the bolts in three stages in the sequence shown in Fig 1:
- Stage 1: Tighten the bolts to 20 Nm (15 lb-ft).
- Stage 2: Tighten the bolts to 40 Nm (30 lb-ft).
- Tighten the bolts an additional 105 degrees.
- Raise and support the vehicle. For additional information, refer to JACKING & HOISTING .
- Install the splash shield and the bolts.
- Lower the vehicle.
- Connect the crankshaft position (CKP) sensor electrical connector.
- Connect the main engine electrical connectors.
- Connect the speed control and the accelerator control cables.
- Connect the vacuum hoses.
- Install the oil level indicator and tube. For additional information, refer to OIL LEVEL INDICATOR AND TUBE .
- Install the generator. For additional information, refer to GENERATOR .
- Install the power steering pump and bracket assembly. For additional information, refer to PUMP--ZETEC and PUMP -- 2.0L .
- Connect the fuel line. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
- Install the coolant recovery reservoir. For additional information, refer to INSTALLATION .
- Install the thermostat housing. For additional information, refer to INSTALLATION .
- Install the camshafts. For additional information, refer to CAMSHAFT .
- Install the air cleaner outlet tube.
- Drain the engine oil and install a new oil filter.
- Fill the engine with clean engine oil.
- Run the engine and check for leaks.
CAUTION:
Do not use abrasive grinding discs to remove gasket material; use only plastic manual scrapers. Do not scratch or gouge the aluminum sealing surfaces.
CAUTION:
The bolts are torque-to-yield, new bolts must be installed or engine damage can occur.