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Cylinder Head: Installation

WARNING: This page is about a different car, the 2004 Ford Focus. However, it is still accessible from the selected car via links, so may be relevant.
  1. Using a spatula, remove the gasket residue.
    • Thoroughly clean the threaded holes of the cylinder head bolts.
  2. Check the cylinder head distortion. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  3. Make up two locating studs as shown.
    Fig 1: Identifying Locating Studs
    G04035043Courtesy of FORD MOTOR CO.
    4. NOTE: Install a new cylinder head gasket.
    Fig 2: Installing Cylinder Head Gasket
    G04035044Courtesy of FORD MOTOR CO.
  4. Install the cylinder head gasket.
    1. Position the cylinder head gasket.
    2. Insert the fabricated locating studs.
    3. Check that the locating studs are seated correctly.
  5. Install the cylinder head.
    6. CAUTION: Do not retighten the cylinder head bolts.
    Fig 3: Cylinder Head Torque Sequence
    G04035045Courtesy of FORD MOTOR CO.
  6. Tighten the cylinder head bolts in three stages in the sequence indicated.
    • Stage 1: 20 Nm
    • Stage 2: 40 Nm
    • Stage 3: 90 degrees.
    7. NOTE: Coat the valve tappets with clean engine oil before installation.
  7. Install the valve tappets in order.
  8. Install the generator bracket bolt.
    Fig 4: Installing Generator Bracket Bolt
    G04035046Courtesy of FORD MOTOR CO.
  9. Attach the generator.
    Fig 5: Installing Generator
    G04035047Courtesy of FORD MOTOR CO.
  10. Attach the power steering pump bracket to the cylinder head and cylinder block.
    Fig 6: Attaching Power Steering Pump Bracket To Cylinder Head And Cylinder Block
    G04035048Courtesy of FORD MOTOR CO.
  11. Install the camshafts. For additional information, refer to CAMSHAFTS .
  12. Check the valve clearance and, if necessary, adjust.
  13. Connect the wiring harness to the electric ignition (El) coil and to the engine coolant temperature (ECT) sensor.
    Fig 7: Connecting Wiring Harness To Electric Ignition Coil And To Engine Coolant Temperature Sensor
    G04035049Courtesy of FORD MOTOR CO.
  14. Attach the power steering pipe bracket to the cylinder head.
    Fig 8: Attaching Power Steering Pipe Bracket To Cylinder Head
    G04035050Courtesy of FORD MOTOR CO.
  15. Install the intake manifold lower retaining bolt.
    Fig 9: Installing Intake Manifold Lower Retaining Bolt
    G04035051Courtesy of FORD MOTOR CO.
  16. Connect the catalyst monitor sensor electrical connector and attach it to the bracket.
    Fig 10: Connecting Catalyst Monitor Sensor Electrical Connector
    G04035052Courtesy of FORD MOTOR CO.
  17. Connect the knock sensor electrical connector.
    Fig 11: Connecting Knock Sensor Electrical Connector
    G04035053Courtesy of FORD MOTOR CO.
  18. Install the exhaust manifold. For additional information, refer to EXHAUST MANIFOLD .
    19. NOTE: Install a new thermostat housing gasket.
    Fig 12: Attaching Thermostat Housing
    G04035054Courtesy of FORD MOTOR CO.
  19. Attach the thermostat housing.
  20. Attach the fuel lines.
    • Attach the ground cable to the engine lifting bracket.
    Fig 13: Attaching Fuel Lines
    G04035055Courtesy of FORD MOTOR CO.
  21. Connect the camshaft position (CMP) sensor connector.
    Fig 14: Connecting Camshaft Position Sensor Connector
    G04035056Courtesy of FORD MOTOR CO.
  22. Connect the fuel injector wiring harness.
    Fig 15: Connecting Fuel Injector Wiring Harness
    G04035057Courtesy of FORD MOTOR CO.
  23. Attach the accelerator cable and the speed control cable (if equipped) to the throttle body.
    Fig 16: Attaching Accelerator Cable
    G04035058Courtesy of FORD MOTOR CO.
  24. Connect the vehicle speed control cable.
    1. Attach the vehicle speed control cable to the throttle body.
    2. Connect the inner cable from the throttle body.
    Fig 17: Connecting Vehicle Speed Control Cable
    G04035059Courtesy of FORD MOTOR CO.
  25. Install the splash shield.
    Fig 18: Installing Splash Shield
    G04035060Courtesy of FORD MOTOR CO.
  26. Attach the intake manifold runner control (IMRC) actuator cable to the IMRC lever (intake manifold assembly shown removed for clarity).
    1. Rotate the IMRC lever.
    2. Install the IMRC actuator cable.
    Fig 19: Installing IMRC Actuator Cable
    G04035061Courtesy of FORD MOTOR CO.
  27. Attach the vacuum hoses to the intake manifold.
    Fig 20: Attaching Vacuum Hoses To Intake Manifold
    G04035062Courtesy of FORD MOTOR CO.
  28. Install the air cleaner. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
  29. Attach the brake booster pipe to the intake manifold.
    Fig 21: Attaching Brake Booster Pipe To Intake Manifold
    G04035063Courtesy of FORD MOTOR CO.
  30. Raise and support the vehicle. For additional information, refer to JACKING AND LIFTING .
  31. Connect the oil pressure switch electrical connector.
    Fig 22: Connecting Oil Pressure Switch Electrical Connector
    G04035064Courtesy of FORD MOTOR CO.
  32. Drain and fill the engine with clean engine oil.
  33. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  34. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING .
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