LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 2617 (Engine Mechanical - 2.5L (Hybrid)) >> In-Vehicle Repair >> Cylinder Head >> Installation

Cylinder Head: Installation

WARNING: This page is about a different car, the 2011 Mercury Milan, 2011 Lincoln MKZ, and 2011 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
    NOTE: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.
    NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.
  1. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block in the following sequence.
    1. Remove any large deposits of silicone or gasket material with a plastic scraper.
    2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.
    3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
    4. Apply metal surface prep, following package directions, to remove any traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
  2. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
  3. Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.
  4. Apply silicone gasket and sealant to the locations shown in illustration.
    Fig 1: Locating Silicone Gasket And Sealant Apply Locations
    G07782047Courtesy of FORD MOTOR CO.
  5. Install a new cylinder head gasket.
    6. NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.
    Fig 2: Identifying Cylinder Head Bolts Tightening Sequence
    G07782048Courtesy of FORD MOTOR CO.
  6. Install the cylinder head and 10 new bolts. Tighten the bolts in the sequence shown in illustration in the following 5 stages:
    • Stage 1: Tighten to 5 Nm (44 lb-in).
    • Stage 2: Tighten to 15 Nm (133 lb-in).
    • Stage 3: Tighten to 45 Nm (33 lb-ft).
    • Stage 4: Turn 90 degrees.
    • Stage 5: Turn an additional 90 degrees.
  7. Connect the upper radiator hose, coolant bypass hose, EGR coolant hose, heater hose and coolant vent hose to the engine coolant outlet and the EGR valve.
  8. Connect the EGR valve electrical connector.
  9. Install the catalytic converter. For additional information, refer to EXHAUST SYSTEM -- FUSION, MILAN & MKZ article.
    10. NOTE: Lubricate the valve tappets with clean engine oil.
    Fig 3: Locating Valve Tappet
    G07782049Courtesy of FORD MOTOR CO.
  10. Install the valve tappets in their original positions.
    11. NOTE: Install the camshafts with the alignment notches in the camshafts lined up so the camshaft alignment plate can be installed. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the removal procedure. Failure to follow this procedure can cause severe damage to the valves and pistons.
    NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil.
    Fig 4: Identifying Camshaft Bearing Cap Bolts Tightening Sequence
    G07782050Courtesy of FORD MOTOR CO.
  11. Install the camshafts and bearing caps in their original location and orientation. Tighten the bearing caps in the sequence shown in illustration in 3 stages:
    • Stage 1: Tighten the camshaft bearing cap bolts, one turn at a time, until finger-tight.
    • Stage 2: Tighten the bolts to 7 Nm (62 lb-in).
    • Stage 3: Tighten the bolts to 16 Nm (142 lb-in).
  12. Install the Camshaft Alignment Plate.
    Fig 5: Identifying Camshaft Alignment Plate
    G07782051Courtesy of FORD MOTOR CO.
  13. Install the timing drive components. For additional information, refer to TIMING DRIVE COMPONENTS  in this service information.
  14. Install the VCT oil control solenoid. For additional information, refer to ELECTRONIC ENGINE CONTROLS - FUSION HYBRID, MILAN HYBRID & MKZ HYBRID article.
  15. Install the intake manifold. For additional information, refer to INTAKE MANIFOLD  in this service information.
  16. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING SYSTEM -- (HYBRID) article.
scientia non olet · About LEMON Manuals