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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 358 (Engine - 2.0L ZETEC) >> In-Vehicle Repair >> Cylinder Head >> Installation

Cylinder Head: Installation

WARNING: This page is about a different car, the 2002 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: The cylinder head sealing surfaces are soft metals. Do not use abrasive grinding discs to remove gasket material; use only plastic manual scrapers. Do not scratch or gouge the 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 flatness. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  2. Install a new head gasket on the cylinder block.
    3. CAUTION: The bolts are torque-to-yield, new bolts must be installed or engine damage can occur.
    Fig 1: Installing Head Gasket On Cylinder Block
    G03430295Courtesy of FORD MOTOR CO.
  3. Install the cylinder head and tighten the bolts in three stages using the sequence shown.
    • Stage 1: Tighten the bolts to 20 Nm (15 lb-ft).
    • Stage 2: Tighten the bolts to 40 Nm (30 lb-ft).
    • Stage 3: Tighten the bolts an additional 90 degrees.
  4. Install the special tool.
    Fig 2: Installing Special Tool
    G03430296Courtesy of FORD MOTOR CO.
  5. Remove the engine mount upper bracket.
    Fig 3: Removing Engine Mount Upper Bracket
    G03430297Courtesy of FORD MOTOR CO.
  6. Remove the studs.
    Fig 4: Removing Studs
    G03430298Courtesy of FORD MOTOR CO.
  7. Raise and support the vehicle.
  8. Remove the engine mount lower bracket.
    Fig 5: Removing Engine Mount Lower Bracket
    G03430299Courtesy of FORD MOTOR CO.
  9. Drain the engine oil and install a new oil filter. Fill the crankcase with Super Premium 5W-20 SAE Motor Oil or equivalent meeting Ford specification WSS-M2C153-H.
  10. Lower the vehicle.
  11. Position the power steering bracket back.
    Fig 6: Positioning Power Steering Bracket Back
    G03430300Courtesy of FORD MOTOR CO.
  12. Install the oil level indicator tube and the bolt.
    Fig 7: Installing Oil Level Indicator Tube & Bolt
    G03430301Courtesy of FORD MOTOR CO.
  13. Install the thermostat housing and the bolts.
    Fig 8: Installing Thermostat Housing & Bolts
    G03430302Courtesy of FORD MOTOR CO.
  14. Install the bolt for the power steering pressure hose support bracket.
    Fig 9: Installing Bolt For Power Steering Pressure Hose Support Bracket
    G03430303Courtesy of FORD MOTOR CO.
  15. Connect the ignition coil and the radio interference suppressor electrical connectors.
    Fig 10: Connecting Ignition Coil & Radio Interference Suppressor Electrical Connectors
    G03430304Courtesy of FORD MOTOR CO.
  16. Connect the wiring harness retainer to the intake manifold.
    Fig 11: Connecting Wiring Harness Retainer To Intake Manifold
    G03430305Courtesy of FORD MOTOR CO.
  17. Install the bolt in the generator mounting bracket.
    Fig 12: Installing Bolt In Generator Mounting Bracket
    G03430306Courtesy of FORD MOTOR CO.
  18. Connect the fuel charging wiring harness retainer.
    Fig 13: Connecting Fuel Charging Wiring Harness Retainer
    G03430307Courtesy of FORD MOTOR CO.
  19. Connect the knock sensor (KS) electrical connector.
    Fig 14: Connecting Knock Sensor (KS) Electrical Connector
    G03430308Courtesy of FORD MOTOR CO.
  20. Connect the cylinder head temperature (CHT) sensor electrical connector.
    Fig 15: Connecting Cylinder Head Temperature (CHT) Sensor Electrical Connector
    G03430309Courtesy of FORD MOTOR CO.
  21. Connect the vacuum hose.
    Fig 16: Installing Brake Booster Line & Crankcase Ventilation Hose
    G03430310Courtesy of FORD MOTOR CO.
  22. Connect the vacuum hose.
    Fig 17: Connecting Vacuum Hose
    G03430311Courtesy of FORD MOTOR CO.
  23. Install the generator. For additional information, refer to GENERATORS & REGULATORS .
  24. Connect the fuel line and safety clip.
  25. Install the valve tappets. For additional information, refer to VALVE TAPPETS .
  26. Install the accelerator control cable support bracket bolt.
    Fig 18: Installing Accelerator Control Cable Support Bracket Bolt
    G03430312Courtesy of FORD MOTOR CO.
  27. Drain the engine oil and fill the engine with clean engine oil.
  28. Fill the cooling system. For additional information, refer to ENGINE COOLING .
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