2.2L duratorq-tdci cylinder head gasket replacement

Pic. 5.56. The procedure for loosening the cylinder head bolts.

You will need: All the tools needed to remove the cylinder head cover, timing belt and camshafts.

If a leak of engine oil or coolant is detected at the junction of the block head with the cylinder block, remove the head and replace its gasket. A leak can also occur due to warping of the block head due to overheating.

1. Reduce the pressure in the supply system (see Reducing the pressure in the engine supply system).

2. Drain the liquid from the engine cooling system (see Coolant Change).

3. Remove the air filter and air sleeves (refer to 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 thermostat).

8. Remove a distributive collector of system of injection of fuel.

9. Remove the fuel injectors.

10. Remove the fuel pump.

11. Remove the timing belt (refer to Duratorq-tdci 2.2L Timing Belt Replacement).

12. Turn out nine bolts of fastening of a back cover of a belt of a drive of the gas-distributing mechanism and remove a cover.


13. Squeezing the clamps with pliers and sliding them along the hoses, disconnect the hoses of the cooling system.

NOTE: Install new clamps when assembling.

14. Remove the cylinder head cover (refer to 2.2L Duratorq-tdci Cylinder Head Cover Seals Replacement).

15. Remove camshafts (see 2.2L Duratorq-tdci Engine Camshaft Replacement).

16. Loosen the ten cylinder head bolts in the order shown in fig. 5.56, and then finally unscrew the head mounting bolts and remove them together with the washers.

WARNING: The cylinder head bolts must only be removed when the engine is cold.

17. Remove the cylinder head.

USEFUL ADVICE: It is more convenient 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 up a head of the block on lack of a buckling. To do this, placing the ruler with an edge on the surface of the head, first in the middle along, then across and diagonally, measure the gap between the surface of the head and the ruler with a feeler gauge. Replace the cylinder head if the clearance is greater than 0.1mm.

20. Establish a lining and establish a head of the block of cylinders in an order, the return to removal, taking into account the following: – Remove from carving openings of bolts of fastening of a head of the block of cylinders oil or a cooling liquid which got there at removal of a head; – Be sure to install a new block head gasket, its reuse is not allowed; - Lubricate the bolts with engine oil; – tighten bolts on the cold engine in an order, the return shown on fig. 5.56, in three stages: 1st - with a torque of 20 Nm (2 kgf·m); 2nd - torque 60 Nm (6 kgf·m); 3rd - tighten by an angle of 220°.


21. Establish all removed details and knots in an order, the return to removal. After installing the camshafts and the timing belt, check and, if necessary, adjust the clearances in the valve drive.

22. Adjust the tension of the timing belt (refer to Duratorq-tdci 2.2L Timing Belt Replacement).

23. Fill liquid into the engine cooling system (see Coolant Change).