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Home >> Ford >> 2002 >> Focus ZTS, Automatic >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 3 (Engine - 2.0L SPI) >> In-Vehicle Repair >> Cylinder Head >> Installation

Cylinder Head: Installation

WARNING: This page is about a different variant/trim than selected.
    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 article .
  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 N.m.
    2. Back the bolts off 1/2 turn.
    3. Tighten the bolts in sequence shown to 50 N.m.
    4. Rotate all the bolts in a single sequence an additional 180 degrees in two steps of 90 degrees each.
      Fig 1: Identifying Tightening Sequence Of Cylinder Bolts
      G03432201Courtesy of FORD MOTOR CO.
  4. Install the valve cover.
    Fig 2: Installing Valve Cover With Torque Specifications
    G03432202Courtesy 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
      G03432203Courtesy of FORD MOTOR CO.
  6. Connect the crankshaft position sensor (CKP) electrical connector.
    Fig 4: Connecting Crankshaft Position Sensor (CKP) Electrical Connector
    G03432204Courtesy 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 With Torque Specifications
    G03432205Courtesy of FORD MOTOR CO.
  9. Install the heat shield.
    1. Heat shield
    2. Power steering tube
      Fig 6: Installing Heat Shield
      G03432206Courtesy of FORD MOTOR CO.
  10. Raise and support the vehicle.
  11. Connect the knock sensor (KS) and the oil pressure switch electrical connector.
    Fig 7: Connecting Knock Sensor (KS) And Oil Pressure Switch Electrical Connector
    G03432207Courtesy of FORD MOTOR CO.
  12. Connect the CMS sensor electrical connector.
    Fig 8: Connecting CMS Sensor Electrical Connector
    G03432208Courtesy 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 With Torque Specifications
      G03432209Courtesy of FORD MOTOR CO.
  14. Lower the vehicle.
  15. Install the fuel hose.
    Fig 10: Installing Fuel Hose
    G03432210Courtesy of FORD MOTOR CO.
  16. Install the coolant hose.
    Fig 11: Installing Coolant Hose
    G03432211Courtesy of FORD MOTOR CO.
  17. Install the coolant hoses to the thermostat housing.
    Fig 12: Installing Coolant Hoses To Thermostat Housing
    G03432212Courtesy of FORD MOTOR CO.
  18. Install the oil level indicator tube.
    Fig 13: Installing Oil Level Indicator Tube
    G03432213Courtesy of FORD MOTOR CO.
  19. Install the vacuum hose.
    Fig 14: Installing Vacuum Hoses (1 Of 2)
    G03432214Courtesy of FORD MOTOR CO.
  20. Install the vacuum hoses.
    1. EVAP
    2. Brake sevo
    3. Delta Pressure Feedback Electronic System Sensor (DPFE)
    4. EGR-valve
      Fig 15: Installing Vacuum Hoses (2 Of 2)
      G03432215Courtesy of FORD MOTOR CO.
  21. Connect the HO2S electrical connector.
    Fig 16: Connecting HO2S Electrical Connector
    G03432216Courtesy of FORD MOTOR CO.
  22. Connect both PCM connectors.
    Fig 17: Connecting PCM Connectors
    G03432217Courtesy 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
      G03432218Courtesy of FORD MOTOR CO.
  24. Install the accelerator cable.
    1. Install the cable.
    2. Install the plastic clip.
      Fig 19: Installing Accelerator Cable
      G03432219Courtesy 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: Connecting MAF Electrical Connector
        G03432220Courtesy of FORD MOTOR CO.
  26. Change the engine oil (and the oil filter).
  27. Fill the cooling system. For additional information, refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING article .
  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 .
  30. Start the engine and check for leaks.
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