Fig. 5.56. The order of loosening the tightening of the cylinder head mounting bolts.
You will need: all the tools necessary to remove the cylinder head cover, timing belt and camshafts.
If you detect a leak of engine oil or coolant at the junction of the cylinder head and the cylinder block, remove the head and replace its gasket. The leak may also occur due to warping of the cylinder head due to overheating.
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 filter and air supply hoses (see Removing and installing the air filter and intake silencer).
4. Remove the accessory drive belt.
5. Remove the fuel filter.
6. Remove the exhaust manifold.
7. Remove the thermostat (see Removing and installing the thermostat).
8. Remove the fuel injection manifold.
9. Remove the fuel injectors.
10. Remove the fuel pump.
11. Remove the timing belt (see Replacing the timing belt of the 2.2L duratorq-tdci engine).
12. Remove the nine bolts securing the rear timing belt cover and remove the cover.
13. Using pliers, squeeze the clamps and slide them along the hoses to disconnect the cooling system hoses.
NOTE: Install new clamps when reassembling.
14. Remove the cylinder head cover (see Replacing the cylinder head cover seals on a 2.2L duratorq-tdci engine).
15. Remove the camshafts (see Replacing camshafts on a 2.2L duratorq-tdci engine).
16. Loosen the ten cylinder head mounting bolts in the order shown in Fig. 5.56, 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.
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 on the edge of the head surface first in the middle along, then across and diagonally, and measure the gap between the head surface and the ruler with a feeler gauge. Replace the cylinder head if the gap is more than 0.1 mm.
20. Install the gasket and install the cylinder head in the reverse order of removal, taking into account the following: – remove any oil or coolant from the threaded holes of the cylinder head mounting bolts that got there when removing the head; – be sure to install a new cylinder head gasket, reusing it is not allowed; – lubricate the bolts with engine oil; – tighten the bolts on a cold engine in the reverse order to that shown in Fig. 5.56, in three stages: 1st – with a torque of 20 N·m (2 kgf·m); 2nd – torque 60 Nm (6 kgf·m); 3rd – tighten to an angle of 220°.
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.
22. Adjust the timing belt tension (see Replacing the timing belt of the 2.2L duratorq-tdci engine).
23. Fill the engine cooling system with fluid (see Replacing the coolant).
The article was taken in its entirety from the specified website: FordBook