Duratec

IN-VEHICLE REPAIR





Cylinder Head

Name Specification
Sealant, camshaft bearing caps WSK-M2G348-A5
Coolant ESD-M97B49-A
Sealant WS-M4G348-A5
Sealant remover WSK-M2G348-A4
Engine oil WSS-M2C153-H
Silicone grease for spark plug connector seal A960-M1C171-M

Removal
1. Release the fuel system pressure. For additional information, refer to Powertrain Management, Fuel Delivery and Air Induction.

2. Disconnect the battery. For additional information, refer to Starting and Charging, Battery.

3. WARNING: To prevent the risk of scalding, place a thick cloth over the filler cap before opening the cooling circuit. Failure to do so may result in personal injury.

Release the coolant system pressure.

4. Raise the vehicle.





5. Drain the coolant from the radiator.
^ Allow the coolant to drain into a suitable container.
^ Install the radiator drain plug after draining the coolant.





6. Detach the brake booster pipe from the intake manifold.
^ Release the quick release coupling and detach the brake booster pipe.





7. Disconnect the oil pressure switch electrical connector
8. Lower the vehicle.
9. Remove the air cleaner.





10. Detach the accelerator cable from the throttle body.





11. Disconnect the vacuum hoses from the intake manifold.





12. Disconnect the fuel injector wiring harness.





13. Disconnect the camshaft position (CMP) sensor electrical connector.

14. WARNING: Escaping fuel. Observe the safety regulations for working with fuel.





Detach the fuel lines.
^ Detach the ground cable.
15. Remove the exhaust manifold. For additional information, refer to Exhaust System, Exhaust Manifold.





16. Detach the thermostat housing.





17. Detach the power steering pipe bracket from the cylinder head.





18. Detach the power steering pump bracket from the cylinder head and cylinder block.





19. Detach the generator.
1. Loosen the bolt.
2. Remove the bolt





20. Disconnect the wiring harness from the electronic ignition (El) coil and from the engine coolant temperature (ECT) sensor.





21. Remove the upper bolt from the generator bracket.
22. Remove the camshafts. For additional information, refer to Engine, Camshaft, Lifters and Push Rods.

23. CAUTION: Cylinder head bolts can only be used twice, mark the bolts to indicate usage.

CAUTION: The cylinder head must be cooled to ambient temperature.

NOTE: Evenly loosen the cylinder head bolts in the sequence shown.





Remove the cylinder head bolts
24. Remove the cylinder head.

Installation
1. Remove gasket residue with seal remover and a spatula.
^ Thoroughly clean the threaded holes of the cylinder head bolts.
2. Check the cylinder head deformation. For additional information, refer to Engine, Cylinder Head Assembly.





3. Make up two locating studs as shown.

4. NOTE: Install a new cylinder head gasket.





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.

Cylinder Head Torque Sequence:

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.

Install the valve tappets.
8. Install the camshafts. For additional information, refer to Engine, Camshaft, Lifters and Push Rods.

9. Lower the vehicle.





10. Attach the power steering pump bracket to the cylinder head and cylinder block.





11. Install the generator bracket bolt.





12. Connect the wiring harness to the electric ignition (El) coil and to the engine coolant temperature (ECT) sensor.





13. Attach the generator.





14. Attach the power steering pipe bracket to the cylinder head.
15. Install the exhaust manifold. For additional information, refer to Exhaust System, Exhaust Manifold.

16. NOTE: Install a new thermostat housing gasket.





Attach the thermostat housing.





17. Attach the fuel lines.





18. Connect the camshaft position (CMP) sensor connector.





19. Connect the fuel injector wiring harness





20. Attach the accelerator cable and the speed control cable (if equipped) to the throttle body.





21. Attach the vacuum hoses to the intake manifold.
22. Install the air cleaner.

23. Raise and support the vehicle.





24. Connect the oil pressure switch electrical connector.





25. Attach the brake booster pipe to the intake manifold.