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Home >> Ford >> 2003 >> Focus SVT, 2D Hatchback >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 1 (Engine-2.0L ZETEC) >> 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 Locating Studs
    G01614686Courtesy 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 Cylinder Head Cover Gasket On Cylinder Block
      G01614687Courtesy 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 Nm
    • Stage 2: 40 Nm
    • Stage 3: 90 degrees.
    • Apply engine oil to the tappets and insert them.
      Fig 3: Cylinder Head Bolts Tightening Sequence
      G01614688Courtesy of FORD MOTOR CO.
  8. Apply sealant to camshaft bearing cap numbers 0 and 5 in the areas shown.
    Fig 4: Identifying Sealant Application Surface Of Camshaft Bearing Cap
    G01614689Courtesy 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: Locating Camshaft Bearing Cap Lubrication Hole
      G01614690Courtesy 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 Nm
    • Stage 2: 19 Nm
      Fig 6: Camshaft Bearing Caps Bolts Tightening Sequence
      G01614691Courtesy of FORD MOTOR CO.
  12. 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.
      Fig 7: Attaching Timing Belt Pulleys
      G01614692Courtesy of FORD MOTOR CO.
    • Attach the timing belt pulleys.
  13. Install the timing belt. For additional information, refer to TIMING BELT  .
  14. Lower the vehicle.
  15. Attach the power steering pump bracket.
    1. Screw in the upper bolts.
    2. Insert the lower studs.
    • Tighten the bolts and nuts.
      Fig 8: Attaching Power Steering Pump Bracket
      G01614693Courtesy of FORD MOTOR CO.
  16. Install the upper bolt to the generator bracket.
    Fig 9: Installing Upper Bolt To Generator Bracket
    G01614694Courtesy of FORD MOTOR CO.
  17. Attach the generator.
    Fig 10: Attaching Generator
    G01614695Courtesy of FORD MOTOR CO.
  18. Attach the oil level indicator tube and the power steering pipe bracket.
    Fig 11: Attaching Oil Level Indicator Tube And Power Steering Pipe Bracket
    G01614696Courtesy of FORD MOTOR CO.
  19. Attach the catalytic converter to the exhaust manifold.
    Fig 12: Attaching Catalytic Converter To Exhaust Manifold
    G01614697Courtesy of FORD MOTOR CO.
  20. Attach the thermostat housing with new gasket.
    Fig 13: Attaching Thermostat Housing
    G01614698Courtesy of FORD MOTOR CO.
  21. Attach the heat shield.
    Fig 14: Attaching Heat Shield
    G01614699Courtesy of FORD MOTOR CO.
  22. Attach the fuel lines.
    Fig 15: Attaching Fuel Lines
    G01614700Courtesy of FORD MOTOR CO.
  23. Connect the camshaft position (CMP) sensor.
    Fig 16: Connecting Camshaft Position Sensor
    G01614701Courtesy of FORD MOTOR CO.
  24. Connect the fuel injector wiring.
    Fig 17: Connecting Fuel Injector Wiring
    G01614702Courtesy of FORD MOTOR CO.
  25. Attach the EGR valve with a new gasket and EGR pipe bracket.
    Fig 18: Attaching EGR Valve And EGR Pipe Bracket
    G01614703Courtesy of FORD MOTOR CO.
  26. Attach the accelerator cable and the speed control cable (if equipped).
    Fig 19: Attaching Accelerator Cable And Speed Control Cable
    G01614704Courtesy of FORD MOTOR CO.
  27. Push on the vacuum hoses.
    Fig 20: Pushing On Vacuum Hoses
    G01614705Courtesy of FORD MOTOR CO.
  28. Attach the air filter housing.
    • Press the air filter housing into the rubber bushings.
    1. Push on the mass air flow (MAF) sensor multiplug.
    2. Attach the PCV hose.
    3. Attach the intake hose.
      Fig 21: Attaching Air Filter Housing
      G01614706Courtesy of FORD MOTOR CO.
  29. Raise and support the vehicle. For additional information, refer to JACKING & HOISTING .
  30. Push on the oil pressure switch electrical connector.
    Fig 22: Pushing On Oil Pressure Switch Electrical Connector
    G01614707Courtesy of FORD MOTOR CO.
  31. Attach the brake booster pipe and the PCV hose to the intake manifold.
    Fig 23: Attaching Brake Booster Pipe And PCV Hose To Intake Manifold
    G01614708Courtesy of FORD MOTOR CO.
    32. 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.
  32. 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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