To replace the cylinder head gasket on a 1.6L Duratec Ti-VCT engine, follow these steps:.
You will need: all the tools necessary to remove the cylinder head cover, timing belt, camshafts, exhaust manifold, as well as TORX T25 and T55 keys, a flat-blade screwdriver, pliers, and side cutters.
1. Reduce the pressure in the fuel system (see Reducing pressure in the engine fuel system).
2. Drain the fluid from the engine cooling system (see Replacing the coolant).
3. Remove the air supply hose (see Removing and installing the air filter and intake silencer).
4. Remove the crankcase ventilation system pipe (see Cleaning the crankcase ventilation system).
5. Squeeze the clips and disconnect the wiring harness connector from the ignition coil.
6. Remove all spark plugs (see Replacing and servicing spark plugs).
7. Remove the cylinder head cover (see Replacing the cylinder head cover gasket).
8. Remove the timing belt (see Checking and replacing the timing belt of the 1.6L Duratec Ti-VCT engine).
Fig. 5.25. Rear cover of the timing drive of the 1.6L Duratec Ti-VCT engine.
9. Unscrew the three bolts securing the rear cover of the timing drive (Fig. 5.25) and remove the cover.
10. Remove the camshafts (see Replacing the camshafts).
11. Remove the catalytic converter (see Removing and installing the catalytic converter and replacing its gasket).
12. Disconnect the fuel supply line from the fuel rail by squeezing the clamps of the connecting sleeve.
13. Remove the two screws securing the fuel supply line holders and move the line to the side.
14. Remove the injector electrical connector rail (see Removing and installing the fuel rail).
15. Remove the screw securing the oil level indicator bracket.
16. Disconnect the brake booster and purge valve hoses from the intake pipe.
17. Using pliers, squeeze the clamps and slide them along the hoses, disconnect the hose to the cooling system radiator from the water jacket outlet pipe…
18….and the hose to the interior heater radiator.
19. Slide the lock up…
20….and disconnect the wiring harness connector from the throttle body cover.
21. Squeeze the retainer and disconnect the wiring harness connector secured to the cylinder head bracket.
22. Use side cutters to cut the plastic ties securing the wiring harness to the cylinder head bracket.
NOTE: Clamps are single use. Install new clamps during assembly.
23. Press the lock and disconnect the wiring harness connector from the coolant temperature sensor.
24. Remove the two lower intake pipe mounting bolts.
Fig. 5.26. The order of loosening the tightening of the cylinder head bolts of the 1.6 l Duratec Ti-VCT engine.
25. Loosen the ten cylinder head mounting bolts in the order shown in Fig. 5.26, finally unscrew the head mounting bolts and remove them together with the washers.
WARNING: The cylinder head bolts may only be removed when the engine is cold.
26. Remove the cylinder head assembly with the intake pipe and throttle assembly, as well as the gasket installed underneath.
USEFUL TIP: It is easier to remove the cylinder head with an assistant, as it is quite heavy.
27. Clean the mating surfaces of the head and block.
28. Check the cylinder head for warpage. To do this, place a ruler edgewise on the surface of the head, first in the middle along, then across and diagonally, and measure the gap between the surface of the head and the ruler with a feeler gauge. Replace the cylinder head if the gap is greater than 0.1 mm.
29. Install the cylinder head in the reverse order of removal, taking into account the following:
– remove any oil or coolant that got into the threaded holes of the cylinder head mounting bolts when removing the head;
– be sure to install a new cylinder head gasket, reusing it is not allowed;
– lubricate the bolts with engine oil;
Fig. 5.27. Tightening sequence of cylinder head bolts for the 1.6L Duratec Ti-VCT engine.
– tighten the bolts on a cold engine in the order shown in Fig. 5.27, in three stages:
- 1st – torque 15 N·m (1.5 kgf·m);
- 2nd – torque 30 N·m (3.0 kgf·m);
- 3rd – turn it to an angle of 90°.
30. Install all removed parts and assemblies in the reverse order of removal. After installing the camshafts and timing belt, check and, if necessary, adjust the valve clearances (see Adjusting valve clearances).
31. Adjust the timing belt tension (see Checking and replacing the timing belt on the 1.6L Duratec TI-VCT engine).
For replacing the cylinder head gasket of 2.0L and 2.3L Duratec-HE engines perform the following operations.
You will need: all the tools necessary to remove the cylinder head cover, timing belt, camshafts, exhaust manifold, as well as TORX T25 and T55 keys, a flat-blade screwdriver, pliers, and side cutters.
1. Reduce the pressure in the fuel system (see Reducing pressure in the engine fuel system).
2. Drain the fluid from the engine cooling system (see Replacing the coolant).
3. Remove the air supply hose (see Removing and installing the air filter and intake silencer).
4. Squeeze the clips and disconnect the wiring harness connector from the ignition coil.
5. Remove all spark plugs (see Replacing and servicing spark plugs).
6. Remove the cylinder head cover (see Replacing the cylinder head cover gasket).
7. Remove the timing chain (see Replacing the timing chain of the 2.0 and 2.3 L Duratec-HE engines).
8. Remove the camshafts (see Replacing camshafts.
9. Remove the catalytic converter (see Removing and installing the catalytic converter and replacing its gasket).
10. Slide the lock…
11….and disconnect the wiring harness connector from the throttle body cover.
12. Disconnect the fuel line from the fuel rail (see Removing and installing the fuel rail).
13. Disconnect the purge hose from the nipple on the intake pipe.
14. Remove the intake pipe assembly with the throttle body (see Replacing the intake manifold gasket).
15. Disconnect the hose to the interior heater radiator and the supply hose to the engine cooling system radiator from the coolant distributor.
Fig. 5.28. The procedure for loosening the cylinder head bolts of the 2.0 l Duratec-HE engine.
Fig. 5.29. The procedure for loosening the cylinder head bolts of the 2.3L Duratec-HE engine.
16. Loosen the ten cylinder head mounting bolts in the order shown in Fig. 5.28 and 5.29 (depending on the engine type), then completely unscrew the head mounting bolts and remove them together with the washers.
WARNING: The cylinder head bolts may only be removed when the engine is cold.
17. Remove the cylinder head and the gasket installed underneath it.
USEFUL TIP: It is easier to remove the cylinder head with an assistant, as it is quite heavy.
18. Clean the mating surfaces of the head and block.
19. Check the cylinder head for warpage. To do this, place a ruler edgewise on the surface of the head, first in the middle along, then across and diagonally, and measure the gap between the surface of the head and the ruler with a feeler gauge. Replace the cylinder head if the gap is greater than 0.1 mm.
20. Install the cylinder head in the reverse order of removal, taking into account the following:
– remove any oil or coolant that got into the threaded holes of the cylinder head mounting bolts when removing the head;
– be sure to install a new cylinder head gasket, reusing it is not allowed;
– lubricate the bolts with engine oil;
Fig. 5.30. Tightening sequence of the cylinder head bolts for the 2.0L Duratec-HE engine.
– Tighten the bolts on a cold 2.0L Duratec-HE engine in the order shown in Fig. 5.30, in three stages:
- 1st – torque 15 N·m (1.5 kgf·m);
- 2nd – torque 30 Nm (3 kgf·m);
- 3rd – turn it to an angle of 90°.
NOTE: Tighten the 2.3L Duratec-HE engine bolts in the reverse order to that shown in Fig. 5.29, in four stages: 1st - 5 N·m (0.5 kgf·m); 2nd – torque 15 N·m (1.5 kgf·m); 3rd – torque 45 Nm (4.5 kgf·m); 4th – turn it to an angle of 90°.
21. Install all removed parts and assemblies in the reverse order of removal. After installing the camshafts and timing belt, check and, if necessary, adjust the valve clearances (see Adjusting valve clearances).
22. Adjust the timing chain tension (see Replacing the timing chain of the 2.0 and 2.3 L Duratec-HE engines).
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