Removing and installing the cylinder head cover (Mondeo 1 and 2)

Front cylinder head

Removal

1. Disconnect the negative battery cable (Chapter 5, Section 1).

2. Unscrew the bolts of the plastic cover secured to the top of the front cylinder head. Remove the cover and release the coolant hose.

3. Disconnect the crankcase ventilation hoses from each side of the intake air duct that runs from the air cleaner to the throttle body.

4. Loosen the clamp and disconnect the vacuum hose.

5. Loosen the two clamps and disconnect the intake air duct from the throttle body and air cleaner. Remove the air duct.

6. Disconnect the two brake booster vacuum hoses from the upper section of the intake manifold.

7. Disconnect the throttle cable bracket and the EGR valve. To do this, release the lock and disconnect the wiring connector. Disconnect the wiring from the idle air control valve and the throttle position sensor. Disconnect the vacuum hose from the EGR valve. Then unscrew the bolts and remove the valve. Remove the gasket.

8. Disconnect the positive crankcase ventilation hose and disconnect the wiring and vacuum hose from the electronic vacuum regulator.

9. Unscrew the bolts in the reverse order shown in Fig. 5.20 and remove the upper section of the intake manifold. Remove the gaskets.

10. Unscrew the bolts securing the intake system drive with the resonator to the cylinder head cover. Unfasten the wiring and cable and move them to the side. If necessary, disconnect the wiring (see Fig. 5.a-d).









11. Taking into account the position of the high-voltage wires and marking them if necessary, disconnect the wires from the spark plugs. Remove the wire support bracket from the right engine mount (see Fig. 5.11, a, b).





12. Release the cooling system hose from the clamp and remove the bracket. Disconnect the crankcase ventilation hose from the branch pipe on the top of the cylinder head cover (see Fig. 5.12).



13. Disconnect the wiring from the cylinder head cover.

14. In the reverse order to that shown in Fig. 5.16c, sequentially unscrew the cylinder head cover bolts, and then remove the cover and gaskets (see Fig. 5.14, a, b).

Installation

15. Make sure that the mating surfaces of the cover and cylinder head are dry and clean. Apply an 8 mm diameter bead of sealant to the joints between the MGR cover and the cylinder head.

16. Install new spark plug gaskets in the cylinder head cover. Then install the peripheral gasket in its groove (see Fig. 5.16,a,b). Install the cylinder head cover and tighten the bolts to the required torque in the sequence shown in Fig. 5.16,c. Make sure that the round section sealing grooves are installed correctly on the bolts.





17. Secure the wiring to the cylinder head cover. Install the bracket and secure the cooling system hose with a clamp.



18. Connect the high-voltage wires to the spark plugs and secure them to the bracket located on the right engine support.

19. Install the intake system drive with the resonator and connect the wiring to it (see Fig. 5.19, a, b).



20. Install the upper section of the intake manifold together with the gaskets. Tighten the bolts to the specified torque as shown in Fig. 5.20.



21. Install the EGR hose. Connect the vacuum hose and wiring to the electronic vacuum regulator.



22. Install the EGR valve on a new gasket and tighten the bolts. Connect the vacuum hose. Connect the wiring to the idle air control valve and throttle position sensor. Install the retainer. Install the cable bracket.

23. Connect the two vacuum hoses to the upper section of the intake manifold.

24. Attach the intake air duct to the throttle body and air cleaner and tighten the clamps.

25. Connect the vacuum hose and tighten the clamp.

26. Connect the crankcase ventilation hoses to both sides of the intake air duct from the air cleaner to the throttle body.

27. Install the plastic cover on top of the front cylinder head. Secure the coolant hose. Tighten the cover bolts.

28. Connect the negative battery cable (Chapter 5, Section 1).

Note: To restore the engine management system settings due to the battery being disconnected, a mileage of about 16 km is required. In this case, the engine may not operate normally.

Rear cylinder head

Removal

29. Disconnect the negative battery cable (Chapter 5, Section 1).

30. Unscrew the bolts of the plastic cover (coolant pump pulley) secured to the top of the front cylinder head. Remove the cover and release the coolant hose.

31. Disconnect the crankcase ventilation hoses from each side of the intake air duct running from the air cleaner to the throttle body.

32. Loosen the clamp and disconnect the vacuum hose.

33. Loosen the two clamps and disconnect the intake air duct from the throttle body and air cleaner. Remove the air duct.

34. Disconnect the two brake booster vacuum hoses from the upper section of the intake manifold.



35. Remove the throttle cable bracket and the EGR valve. To do this, release the lock and disconnect the wiring connector. Disconnect the wiring from the idle air control valve and the throttle position sensor. Disconnect the vacuum hose from the EGR valve. Then unscrew the bolts and remove the valve. Remove the gasket.

36. Disconnect the positive crankcase ventilation hose and disconnect the wiring and vacuum hose from the electronic vacuum regulator. Also disconnect the crankcase ventilation hose from the cover on its top (see Fig. 5.36).



37. Unscrew the bolts in the reverse order shown in Fig. 5.20 and remove the upper section of the intake manifold. Remove the gaskets.

38. Taking into account the position of the high-voltage wires and marking them if necessary, disconnect the wires from the spark plugs. Remove the wire support bracket from the right engine mount.

39. Unscrew the bolts and remove the injector wiring channel.

40. Remove the bolts and ignition coil assembly. Disconnect the wiring and release it from the fasteners. Remove the ground wire and the radio interference damper.

41. Remove the bolt and remove the front wiring harness bracket from the front cylinder head cover. Then remove the rear wiring harness bracket from the rear cylinder head cover (see Fig. 5.41).





42. Disconnect the wiring, then unscrew the wiring harness bracket bolts from the rear cylinder head cover (see Fig. 5.42).



43. In the reverse order to that shown in Fig. 5.45,a, sequentially unscrew the cylinder head cover bolts, and then remove the cover and gaskets (see Fig. 5.43.a,b).

Installation

44. Make sure that the mating surfaces of the cover and cylinder head are dry and clean. Apply an 8 mm diameter bead of sealant to the joints between the MGR cover and the cylinder head.

45. Install new spark plug gaskets in the cylinder head cover. Then install the peripheral gasket in its groove. Install the cylinder head cover and tighten the bolts to the required torque in the sequence shown in Fig. 5.45,a. Make sure that the O-rings are correctly installed on the bolts (see Fig. 5.45,b).



46. Secure the wiring channel to the rear cylinder head cover.

47. Install and secure the front wire harness bracket to the front cylinder head cover. Then install and secure the rear wire harness bracket to the rear cylinder head cover.

48. Install the ignition coil assembly and tighten the bolts. Connect the wiring and secure it. Install the ground wire and radio interference damper.

49. Install the injector wiring channel and tighten the bolts.

50. Connect the high-voltage wires to the spark plugs and secure them to the bracket located on the right engine support.

51. Install the upper section of the intake manifold together with the gaskets. Tighten the bolts to the specified torque as shown in Fig. 5.20.

52. Install the EGR hose. Connect the vacuum hose and wiring to the electronic vacuum regulator.

53. Install the EGR valve on a new gasket and tighten the bolts. Connect the vacuum hose. Connect the wiring to the idle air control valve and throttle position sensor. Install the retainer. Install the cable bracket.

54. Connect the two vacuum hoses to the upper section of the intake manifold.

55. Attach the intake air duct to the throttle body and air cleaner and tighten the clamps.

56. Connect the vacuum hose and tighten the clamp.

57. Connect the crankcase ventilation hoses to both sides of the intake air duct from the air cleaner to the throttle body.

58. Install the plastic cover on top of the front cylinder head. Secure the coolant hose. Tighten the cover bolts.

59. Connect the negative battery cable (Chapter 5, Section 1). Note: To restore the engine management system settings due to the battery being disconnected, a mileage of approximately 16 km is required. In this case, the engine may not operate normally.