Cylinder Head Assembly: Service and Repair
Cylinder HeadSpecial Tools:
Special Tool(s)
Removal
1. CAUTION: The maximum amount by which the engine management system will adjust the camshaft timing (VCT control unit) is limited to two degrees. As a result of this an extremely high degree of accuracy is required for any work which affects the valve timing.
NOTE:
^ The locations of engine mountings and engine support insulators are described looking from the transaxle to the engine.
^ Operation steps that only apply to certain model variants and therefore do not apply to all vehicles are clearly marked.
Disconnect the battery ground cable.
2. WARNING: When releasing the system pressure, cover the coolant expansion tank cup with a thick cloth to prevent the possibility of scalding. Failure to follow these instructions will result in personal injury.
Release the coolant expansion tank cap.
3. Loosen the RH front wheel nuts.
4. Raise and support the vehicle.
^ Remove the right-hand front wheel.
5. WARNING: When the engine is hot there is a risk of scalding.
Remove the radiator splash shield and drain the coolant.
1. Remove the six bolts.
2. Unscrew the radiator drain plug.
6. Remove the power steering pump lower bolts.
7. Disconnect the brake booster line and the crankcase ventilation hose from the intake manifold.
8. Disconnect the oil pressure switch and the Knock Sensor (KS) electrical connector
9. Lower the vehicle.
10. Remove the intake pipe.
1. Disconnect the Mass Air Flow (MAF) sensor electrical connector.
2. Disconnect the Intake Air Temperature (IAT) sensor electrical connector.
3. Remove the bolt and the two nuts.
11. Remove the Air Cleaner (ACL).
1. Disconnect the crankcase ventilation hose.
2. Disconnect the intake hose.
12. Disconnect the speed control cable.
1. Disconnect the cable from throttle valve.
2. Move the cable up and down and pull it out of the retaining bushing.
3. Press the retaining bushing out of the bracket.
13. Disconnect the throttle cable.
1. Remove the plastic clip and position the throttle cable to one side.
2. Unhook the cable.
14. Disconnect the wiring harness rail and the vacuum hoses.
^ Disconnect the cylinder head wiring harness electrical connector.
^ Disconnect the vacuum hoses.
^ Unscrew the upper wiring harness rail bolts on the intake manifold.
15. Disconnect the starter motor positive lead.
^ Remove the undershield.
^ CAUTION: Do not bend the fusible element when undoing the nut as there is a risk of it breaking.
Unscrew the nut.
16. Disconnect the electrical connectors.
1. Radio interference suppressor.
2. Ignition coil.
3. Engine Coolant Temperature (ECT) sensor.
4. Power Steering Pressure (PSP) switch.
^ Position the wiring to one side.
17. Remove the thermostat housing.
1. Disconnect the Camshaft Position (CMP) sensor electrical connector.
2. Disconnect the coolant hoses and position to one side.
3. Unscrew the bolts.
18. Detach the Positive Crankcase Ventilation (PCV) line.
19. Remove the exhaust manifold heat shield.
1. Unscrew the upper bolts.
^ Remove the coolant hose bracket and the engine lifting eye, and pull out the engine oil level indicator tube.
2. Remove the coolant hose bracket clamp.
3. Remove the lower bolts.
20. Disconnect the Three-Way Catalytic Converter (TWC) from the exhaust manifold.
^ Disconnect the Heated Oxygen Sensor (HO2S) electrical connector.
21. Remove the pulley cover.
22. Detach the power steering pump.
1. Remove the power steering pump bracket from the cylinder head.
2. Remove the upper power steering pump bolts.
23. Remove the generator.
1. Disconnect the generator electrical connectors.
2. Remove the bolts.
24. Remove the generator bracket.
25. Remove the timing belt.
26. Remove the camshaft pulleys.
^ Remove the timing belt.
1. Remove the blanking plug from the exhaust camshaft pulley.
2. NOTE: Hold the camshaft by the hexagon with an open-ended wrench to stop it from turning.
Remove the exhaust camshaft pulley.
3. Remove the intake camshaft pulley.
27. Remove the bolts from the Variable Camshaft Timing (VCT) oil feed flange and the upper part of the engine front cover.
28. NOTE: Working evenly in several stages, unscrew each bolt two turns at a time.
Loosening sequence of the camshaft bearing caps.
29. NOTE: Loosening sequence
Remove the camshafts.
1. Remove the camshaft bearing caps.
2. Remove the intake camshaft.
3. Remove the exhaust camshaft with the VCT control unit.
^ Remove the valve tappets.
30. WARNING: Wait until the cylinder head has cooled down to ambient temperature. Failure to follow this instruction may result in personal injury.
NOTE: Loosening sequence
Remove the cylinder head bolts.
31. Remove the cylinder head.
^ Using the Workshop hoist hook it into the engine lifting eyes; lift off the cylinder head and place it on clean Wooden blocks.
^ Discard the cylinder head gasket.
Installation
1. Preparatory operations
^ CAUTION: Do not damage the cylinder liners. Remove the ring of carbon from the upper edge of the cylinder.
Remove any gasket residues with Gasket Maker F8AZ-19B508-AB meeting Ford specification WSK-M2G348-A5 and a Spatula.
^ Thoroughly clean the threaded bores for the cylinder head bolts.
^ Check the cylinder head distortion.
2. Install the cylinder head.
1. Make sure the upright seat of the guide sleeves.
2. Position a new cylinder head gasket onto the cylinder block.
^ Attach the cylinder head into the workshop hoist by the lifting eyes and position it on the cylinder block.
Cylinder Head Tightening Sequence:
3. CAUTION: The cylinder head bolts must not be tightened more than once.
Install the bolts in the sequence shown in three stages:
^ Stage 1: Tighten bolt 1 through 10 to 20 Nm.
^ Stage 2: Tighten bolt 1 through 10 to 40 Nm.
^ Stage 3: Tighten bolt 1 through 10 to 90 degrees.
4. Install the special tools.
5. NOTE: Use a thumb to press the locating pins of the gasket into the holes.
Press a new gasket into the oil feed flange.
6. Prepare the exhaust camshaft for installation.
1. Insert the oil feed ring into the oil feed flange.
2. Slide both components together onto the exhaust camshaft.
7. Thinly coat camshaft bearing cap No. 5 with Silicone Gasket and Sealant F7AZ-19554-EA meeting Ford specification WSE-M4G323-A4.
8. Insert the camshafts.
^ Lubricate the valve tappets with Super Premium SAE 5W30 Motor Oil XO-5W30-QSP meeting Ford specification WSS-M2C153-H and insert them.
^ Lubricate the camshaft bearings with Super Premium SAE 5W30 Motor Oil XO-SW30-QSP meeting Ford specification WSS-M2C153-H.
^ Insert the intake camshaft.
1. Hold the oil feed flange upwards during installation of the exhaust camshaft.
2. Position the oil feed ring hole right to the top.
3. NOTE: Keep the oil feed flange away from the cylinder head when turning the flange to avoid damaging the gasket.
Turn the oil feed flange till the locating lug is in installation position on the cylinder head.
9. Insert new exhaust camshaft oil seal.
10. NOTE: The numbering is on the outside of the camshaft bearing caps.
Insert the camshaft bearing caps.
11. NOTE:
^ Make sure the upright seat of the exhaust camshaft oil seal during tightening process of camshaft bearing caps.
^ Working evenly in several stages, screw in each bolt two turns at a time.
^ Tighten the caps in the indicated sequence.
Tighten the camshaft bearing bolts.
12. Using the special tool, press in the intake camshaft oil seal.
13. NOTE: Location lug of the oil feed flange is in installation position on the cylinder head during installation.
Screw in the oil feed flange bolts and the upper timing case bolts.
^ Finger-tighten the right-hand bolt.
^ Finger-tighten the left-hand bolt.
1. Tighten the right-hand bolt.
2. Tighten the left-hand bolt.
14. Check that the oil feed ring moves freely.
^ If it is difficult to turn the oil feed ring, loosen the bolts on the oil feed flange and tighten them again as described in step
15. NOTE: If the lug is bent not centered between the oil bores and the mark, install a new exhaust camshaft pulley.
Installation position of the exhaust camshaft pulley.
1. The lug is centered between the oil bores and the mark.
2. The lug must locate in the hole.
16. CAUTION: Do not rotate the crankshaft. Check that it is still resting against the special tool 303-574.
NOTE:
^ Install the bolts but do not tighten at this stage.
^ New O-ring seal for the exhaust camshaft pulley.
Slide the camshaft pulleys onto the camshafts, screw in the bolts and position the new timing belt, working counterclockwise.
1. Install the VCT unit bolt finger tight.
2. Install the camshaft pulley bolt finger tight.
17. Install the timing belt.
18. Raise and support the vehicle.
19. Connect the oil pressure switch and the knock sensor electrical connector.
20. Install the brake booster line and the crankcase ventilation hose to the intake manifold.
21. Screw in the lower power steering pump bolts.
22. Position the right-hand front wheel.
23. Install the lower radiator splash shield.
1. Tighten the coolant drain plug.
2. Install the seven bolts.
24. Lower the vehicle.
25. Secure the right-hand front wheel.
26. Install the generator bracket.
27. Install the generator.
1. Install the bolts.
2. Connect the generator electrical connectors.
28. Install the power steering pump.
1. Install the upper power steering pump bolts.
2. Attach the power steering pump bracket to the cylinder head.
29. Install the coolant expansion tank.
^ Attach the speed control cable (if equipped) to the coolant expansion tank.
30. Install the pulley cover.
31. Connect the IWC to the exhaust manifold.
32. Connect the H02S electrical connector.
33. Install the exhaust manifold heat shield.
^ Insert the oil level indicator tube, and position the coolant hose bracket and the engine lifting eye.
1. Install in the upper bolts.
2. Install the bracket for the tube/hose (A/C).
3. Install the lower bolts.
34. Install the positive crankcase ventilation line clamp.
35. Install the thermostat housing with a new O-ring seal.
1. Connect the CMP sensor electrical connector.
2. Install in the bolts.
3. Connect the coolant hoses.
36. Connect the electrical connectors:
1. Radio interference suppressor.
2. Ignition coil.
3. Engine Coolant Temperature (ECT) sensor.
4. Power Steering Pressure (PSP) switch.
37. Connect the positive lead of the starter motor.
^ CAUTION: Do not bend the fusible element when tightening the nut as there is a risk of breaking it.
Install the nut.
^ Install the cover.
38. Install the wiring harness rail and connect the vacuum hoses.
^ Screw in the upper wiring harness rail bolts.
^ Connect the vacuum hoses.
^ Connect the cylinder head wiring harness electrical connector.
39. Connect the throttle cable.
^ Install the cable in the bracket and slide on the plastic clip.
^ Hook the cable in place.
40. Attach the speed control cable.
1. Press the retaining bush into the bracket.
2. NOTE: An audible click indicates that it has snapped into place.
Slide the cable into the retaining bush.
3. Connect the cable to the throttle valve.
41. Install the Air Cleaner (ACL).
^ Press the ACL into the rubber mountings.
1. Connect the crankcase ventilation hose.
2. Connect the intake hose.
42. Install the intake pipe.
1. Install the bolt and the two nuts.
2. Connect the plug of the MAF sensor electrical connector.
3. Connect the IAT sensor electrical connector.
43. Fill the cooling system.
44. Tighten the right-hand front wheel.
45. 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.
Connect the battery ground cable.
46. Check the fluid levels and correct as necessary.
47. Check the routing of the vacuum hoses and wiring and secure them with Cable ties.
48. NOTE: The engine oil temperature must be at least 80° C.
Super Premium SAE 5W30 Motor Oil XO-5W30-QSP meeting Ford specification WSS-M2C153-H and oil Filter-change.
49. Check the fluid level again and correct as necessary.