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Home >> Ford >> 2000 >> Focus LX, Standard >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 1 (Engine - 2.0L ZETEC-E) >> In-Vehicle Repair >> Cylinder Head >> Installation

Cylinder Head: Installation

WARNING: This page is about a different variant/trim than selected.
  1. General remarks.
    • If necessary, use Special Tool 412-108 to install coolant and ventilation hoses.
  2. Preparatory operations
      CAUTION: Do not damage the cylinder liner surfaces. Remove carbon deposits from the top edge of the cylinder.
    • Remove gasket residue with seal remover and a spatula.
    • Thoroughly clean the threaded holes of the cylinder head bolts.
  3. Check the cylinder head deformation. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  4. Make up two locating studs as shown.
    Fig 1: Identifying Stud
    G03431742Courtesy of FORD MOTOR CO.
  5. Install a new cylinder head cover gasket on the cylinder block.
    1. Position a new cylinder head gasket.
    2. Insert the fabricated locating studs.
    3. Check that the locating studs are seated correctly.
      Fig 2: Installing New Cylinder Head Cover Gasket On Cylinder Block
      G03431743Courtesy of FORD MOTOR CO.
  6. Install the cylinder head.
    • Position the cylinder head on the cylinder block.
    7. CAUTION: Do not retighten the cylinder head bolts.
  7. Tighten the cylinder head bolts in three stages in the sequence indicated.
    • Stage 1: 20 N.m
    • Stage 2: 40 N.m
    • Stage 3: 90 degrees.
    • Apply engine oil to the tappets and insert them.
      Fig 3: Identifying Tightening Sequence Of Cylinder Head Bolts
      G03431744Courtesy of FORD MOTOR CO.
  8. Apply sealant to camshaft bearing cap numbers 0 and 5 in the areas shown.
    Fig 4: Applying Sealant To Camshaft Bearing Cap
    G03431745Courtesy of FORD MOTOR CO.
  9. Turn the crankshaft to approximately 60 degrees before TDC on cylinder number 1.
    10. NOTE: Identification numbers are provided on the outer face of the camshaft bearing caps.
  10. Lay the camshaft in place so that none of the cams is at full lift.
    • Lubricate the camshaft and camshaft bearing caps with engine oil.
      Fig 5: Identifying Marking On Outer Face Of Camshaft Bearing Caps
      G03431746Courtesy of FORD MOTOR CO.
    11. NOTE: Screw in the camshaft bearing cap bolts evenly in several stages, in the sequence shown, a half turn at a time and tighten them in two stages.
  11. Tighten the bolts of the camshaft bearing caps.
    • Stage 1: 10 N.m
    • Stage 2: 19 N.m
      Fig 6: Identifying Tightening Sequence Of Camshaft Bearing Cap Bolts
      G03431747Courtesy of FORD MOTOR CO.
  12. Check the valve clearance and if necessary adjust. For additional information, refer to Valve Clearance .
  13. Install the camshaft oil seals.
    • Lubricate the camshaft and oil seal lip with engine oil.
    • Using the special tool install a new oil seal.
      NOTE: Do not tighten the bolts. The camshaft timing pulleys must be able to turn freely on the camshafts.

      Attach the timing belt pulleys.

      Fig 7: Installing Camshaft Oil Seals
      G03431748Courtesy of FORD MOTOR CO.
  14. Install the timing belt. For additional information, refer to TIMING BELT .
  15. Lower the vehicle.
  16. Attach the power steering pump bracket.
    1. Screw in the upper bolts.
    2. Insert the lower studs.
      • Tighten the bolts and nuts.
        Fig 8: Installing Power Steering Pump Bracket
        G03431749Courtesy of FORD MOTOR CO.
  17. Install the upper bolt to the generator bracket.
    Fig 9: Installing Upper Bolt Of Generator Bracket
    G03431750Courtesy of FORD MOTOR CO.
  18. Attach the generator.
    Fig 10: Installing Generator
    G03431751Courtesy of FORD MOTOR CO.
  19. Attach the oil level indicator tube and the power steering pipe bracket.
    20. Fig 11: Installing Oil Level Indicator Tube And Power Steering Pipe Bracket
    G03431752Courtesy of FORD MOTOR CO.
  20. Attach the catalytic converter to the exhaust manifold.
    Fig 12: Installing Catalytic Converter To Exhaust Manifold
    G03431753Courtesy of FORD MOTOR CO.
  21. Attach the thermostat housing with new gasket.
    Fig 13: Installing Thermostat Housing With New Gasket
    G03431754Courtesy of FORD MOTOR CO.
  22. Attach the heat shield.
    Fig 14: Installing Heat Shield
    G03431755Courtesy of FORD MOTOR CO.
  23. Attach the fuel lines.
    Fig 15: Installing Fuel Lines
    G03431756Courtesy of FORD MOTOR CO.
  24. Connect the camshaft position (CMP) sensor.
    Fig 16: Connecting Camshaft Position (CMP) Sensor
    G03431757Courtesy of FORD MOTOR CO.
  25. Connect the fuel injector wiring.
    Fig 17: Connecting Fuel Injector Wiring
    G03431758Courtesy of FORD MOTOR CO.
  26. Attach the EGR valve with a new gasket and EGR pipe bracket.
    Fig 18: Installing EGR Valve With New Gasket And EGR Pipe Bracket
    G03431759Courtesy of FORD MOTOR CO.
  27. Attach the accelerator cable and the speed control cable (if equipped).
    Fig 19: Installing Accelerator Cable And Speed Control Cable
    G03431760Courtesy of FORD MOTOR CO.
  28. Push on the vacuum hoses.
    Fig 20: Connecting Vacuum Hoses
    G03431761Courtesy of FORD MOTOR CO.
  29. Attach the air filter housing.
    • Press the air filter housing into the rubber bushings.
      1. 2. Push on the mass air flow (MAF) sensor multiplug.
      2. 3. Attach the PCV hose.
      3. 4. Attach the intake hose.
        Fig 21: Connecting Mass Air Flow (MAF) Sensor Multiplug
        G03431762Courtesy of FORD MOTOR CO.
  30. Raise and support the vehicle.
  31. Push on the oil pressure switch electrical connector.
    Fig 22: Connecting Oil Pressure Switch Electrical Connector
    G03431763Courtesy of FORD MOTOR CO.
  32. Attach the brake booster pipe and the PCV hose to the intake manifold.
    33. Fig 23: Installing Brake Booster Pipe And PCV Hose To Intake Manifold
    G03431764Courtesy of FORD MOTOR CO.
    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.
  33. Standard finishing operations
    • Connect the battery negative cable.
    • Top up the coolant. For additional information, refer to ENGINE COOLING .
    • Close the coolant expansion tank.
    • Check fluid levels and correct if necessary.
    • Check the routing of vacuum hoses and cables and secure them with cable ties.
    • Check fluid levels again and correct if necessary.
      NOTE: The engine oil temperature must be at least 80°C.

      Change the engine oil and the oil filter. For additional information, refer to GENERAL SPECIFICATIONS .

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