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Fusion 2002.75 (06.2002-)

Engine - 1.4L Duratorq-TDCi (DV) Diesel - Cylinder Head Fusion 2002.75 (06/2002-)
Disassembly and Assembly of Subassemblies

Special Tool(s)

Installer, Valve Stem Oil Seal

303-037 (21-007A)

Compressor, Valve Spring

303-060 (21-024)

Adapter for 303-060

303-060-05 (21-024-05)

Adapter for 303-060

303-060-07 (21-024-07)

Installer, Valve Stem Collets

303-362 (21-156)

Pliers, Valve Stem Oil Seal

303-508 (21-211)
General Equipment
Workshop table
Materials
Name
Specification
Engine oil
WSM-M2C913-B 
Hypoid oil
SQM-2C-9022-AA 

Disassembly

All vehicles
WARNING:
WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may ignite. Failure to follow these instructions may result in personal injury.
  1. Using suitable wooden blocks, position the cylinder head on a workshop table.

  1. Remove the turbocharger lower retaining nuts.
    • Discard the nuts.

  1. Remove the turbocharger.
    • Discard the nuts.

  1. Remove the exhaust manifold.
    • Discard the nuts and the gasket.

  1. Remove the exhaust manifold studs.
    • Discard the studs.

  1. Remove the engine rear lifting eye.

  1. Remove the fuel pump rear support bracket.

  1. Remove the glow plug wiring harness.

  1. Remove the glow plugs.
Vehicles without exhaust gas recirculation (EGR) cooler
  1. Remove the EGR valve.
    • Discard the gasket.
Vehicles with EGR cooler
  1. Remove the EGR valve.
    • Discard the gasket.
All vehicles
  1. Remove the oil pressure relief valve.

  1. Remove the fuel filter support nut.

  1. CAUTION:
    CAUTION:Keep the hydraulic lash adjusters in order for installation.
    Remove the hydraulic lash adjusters.

  1. Using the special tools, remove the valve collets.

  1. CAUTION:
    CAUTION:Keep the valve spring retainers and the valve springs in order for installation.
    Remove the valve springs and the valve spring retainers.

  1. Using the special tool, remove the valve stem seals.
    • Discard the seals.

  1. CAUTION:
    CAUTION:Keep the valves in order for installation.
    Remove the valves.

Assembly

All vehicles
WARNING:
WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may ignite. Failure to follow these instructions may result in personal injury.
  1. Coat the valves with clean hypoid oil.
  1. Grind in the valves.
  1. Clean the valves.

  1. NOTE:
    NOTE:Install new valve stem seals.
    NOTE:
    NOTE:Coat the valve seals with clean engine oil.
    Using the special tool, install the valve stem seals.

  1. Install a valve stem protective sleeve over the valve collet groove.
  1. Coat the valves with clean hypoid oil.

  1. Install the valves.
  1. NOTE:
    NOTE:Only remove the valve stem protective sleeve after the valve stem seals have been installed.
    Remove the valve stem protective sleeves.

  1. Install the valve springs and the valve spring retainers.

  1. Using the special tools, install the valve collets.

  1. Install the hydraulic lash adjusters.

  1. Install the fuel filter support nut.

  1. Install the oil pressure relief valve.
Vehicles without exhaust gas recirculation (EGR) cooler
  1. NOTE:
    NOTE:Install a new EGR valve gasket.
    Install the EGR valve.
Vehicles with EGR cooler
  1. NOTE:
    NOTE:Install a new EGR valve gasket.
    Install the EGR valve.
All vehicles
  1. Install the glow plugs.

  1. Install the glow plug wiring harness.

  1. Install the fuel pump rear support bracket.

  1. Install the engine rear lifting eye.

  1. NOTE:
    NOTE:Install new exhaust manifold studs.
    Install the exhaust manifold studs.

  1. NOTE:
    NOTE:Install new exhaust manifold retaining nuts.
    NOTE:
    NOTE:Install a new exhaust manifold gasket.
    Install the exhaust manifold.

  1. NOTE:
    NOTE:Install new turbocharger retaining nuts.
    Install the turbocharger.

  1. NOTE:
    NOTE:Install new turbocharger lower retaining nuts.
    Install the turbocharger lower retaining nuts.

Assembly > < In-vehicle Repair|Disassembly|Engine