CYLINDER HEAD GASKET REPLACEMENT [YF (2.0L Zetec)]

Camshafts

Removal

1. Remove the camshaft timing sprockets. (See TIMING BELT REMOVAL/INSTALLATION [YF (2.0L Zetec)].)

2. Verify the valve clearance. (See VALVE CLEARANCE ADJUSTMENT [YF (2.0L Zetec)].)

Caution

• Cylinder head camshaft journal caps are numbered on the outside flats to make sure that they are assembled in their original positions. Failure to do so may result in engine damage.

3. Remove the camshafts.

• Loosen the camshaft journal cap bolts in several two-turn passes in the sequence shown.

• Remove the bolts.

• Remove the caps.

4. Inspect the camshafts for wear.

• Discard the oil seals.

Installation

Note

• The front camshaft journal cap must be installed and the bolts tightened to specification within four minutes of sealer application or oil leaks may occur.

1. Coat the sealing surface of the front camshaft journal cap.

Note

• Lubricate the camshaft bearing surfaces with engine oil.

2. Install the camshafts.

• Position the camshafts and camshaft journal caps.

• Install the bolts and tighten the bolts in several two-turn passes using the sequence shown.

3. Verify the valve clearance. (See VALVE CLEARANCE ADJUSTMENT [YF (2.0L Zetec)].)

Note

• The exhaust camshaft oil seal is shown, the intake seal is similar.

4. Using the special tool, install new camshaft front oil seals.

5. Install the camshaft timing sprockets. (See TIMING BELT REMOVAL/INSTALLATION [YF (2.0L Zetec)].)

Camshaft Oil Seal

Removal

1. Remove the camshaft timing sprockets. (See TIMING BELT REMOVAL/INSTALLATION [YF (2.0L Zetec)].)

Note

• The exhaust camshaft oil seal is shown, the intake camshaft oil seal is similar.

2. Using the SST, remove the camshaft oil seals.

Installation

Note

• The exhaust camshaft oil seal is shown, the intake seal is similar.

1. Using the SST, install new camshaft front oil seals.

2. Install the camshaft timing sprockets. (See TIMING BELT REMOVAL/INSTALLATION [YF (2.0L Zetec)].)

Cylinder Head

Removal

1. Remove the ignition coil bracket.

2. Remove the thermostat housing. (See THERMOSTAT REMOVAL/INSTALLATION [YF (2.0L Zetec)].)

3. Remove the positive crankcase ventilation (PCV) tube.

4. Remove the intake manifold. (See INTAKE MANIFOLD REMOVAL/INSTALLATION [YF (2.0L Zetec)].)

5. Remove the exhaust manifold. (See EXHAUST MANIFOLD REMOVAL/INSTALLATION [YF (2.0L Zetec)].)

6. Remove the power steering bracket retainers and position aside.

7. Remove the valve tappets. (See VALVE CLEARANCE ADJUSTMENT [YF (2.0L Zetec)].)

8. Raise the vehicle.

9. Install the engine mount lower bracket.

10. Lower the vehicle.

11. Install the engine mount upper bracket.

12. Remove the SST.

Caution

• The bolts are torque-to-yield and new bolts must be installed or engine damage may occur.

13. Remove the cylinder head bolts in the sequence shown and remove the cylinder head.

• Discard the gasket.

• Discard the bolts.

Installation

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 Section 303-00.

2. Install a new head gasket on the cylinder block.

Caution

• The bolts are torque-to-yield and new bolts must be installed or engine damage may occur.

3. Install the cylinder head and tighten the bolts in three stages using the sequence shown.

• Stage 1: Tighten the bolts to 20 N·m {2.0 kgf·m, 15 ft·lbf}.

• Stage 2: Tighten the bolts to 40 N·m {4.1 kgf·m, 30ft·lbf}.

• Stage 3: Tighten the bolts an additional 90 degrees.

4. Install the SST.

5. Remove the engine mount upper bracket.

6. Raise and support the vehicle.

7. Remove the engine mount lower bracket.

8. Drain engine oil and replace the oil filter. Fill the crankcase with engine oil.

9. Lower the vehicle.

10. Install the valve tappets. (See VALVE CLEARANCE ADJUSTMENT [YF (2.0L Zetec)].)

11. Position the power steering bracket back.

12. Install the exhaust manifold. (See EXHAUST MANIFOLD REMOVAL/INSTALLATION [YF (2.0L Zetec)].)

13. Install the intake manifold. (See INTAKE MANIFOLD REMOVAL/INSTALLATION [YF (2.0L Zetec)].)

14. Install the PCV tube.

15. Install the thermostat housing. (See THERMOSTAT REMOVAL/INSTALLATION [YF (2.0L Zetec)].)

16. Install the ignition coil bracket.