In-vehicle Repair Special Tool(s) | Socket, Cylinder Head Bolt 303-392 | | Remover/Installer, Cooling Hose Clamp 303-397 | Materials Name Specification Grease SA-M1C9107-A | -
CAUTION:Do not smoke or use any kind of naked flame when working on or near any fuel-related components. Highly flammable vapors are always present and may ignite. Failure to observe this instruction can lead to injury. | | -
Release fuel system pressure. For additional information, refer to: Fuel System - 1.6L Duratec-16V (Sigma)/1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (310-00 Fuel System - General Information, Diagnosis and Testing). | | -
Remove the battery tray. For additional information, refer to: Batteriekonsole - 1.6L Duratec-16V (Sigma)/1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (414-01 Batterie, Befestigung und Batteriekabel, Removal and Installation). | | -
Drain the coolant. For additional information, refer to: Kühlsystem entleeren, mit Kühlmittel auffüllen und entlüften (303-03 Kühlsystem - 1.6L Duratec-16V Ti-VCT (Sigma), General Procedures). | | -
Connect the heated oxygen sensor (HO2S) and the left-hand catalyst monitor sensor connectors. - Detach the connector bracket from the cylinder head.
| | -
Connect the heated oxygen sensor (HO2S) and the right-hand catalyst monitor sensor connectors. | 7. Remove the components in the order indicated in the following illustration(s) and table(s). 1 - Exhaust heat shield bolts 5 - Exhaust pipe rubber insulators 7 - Oil dipstick tube bracket bolt 9 - Vacuum line, brake servo 11 - Crankcase breather hose 8. To install, reverse the removal procedure. | -
NOTE:Install a new oil filter. Change the engine oil. For additional information, refer to: Spezifikationen (303-01 Motor - 1.6L Duratec-16V Ti-VCT (Sigma), Specifications). | Removal Details Item 4 : Flexible exhaust pipe nuts. | -
WARNING:Excessive bending of the flexible exhaust pipe can cause damage that may lead to component failure. Protect flexible exhaust pipes with a suitable support sleeve or reinforcement. | Item 6 : Catalytic converter bracket bolts NOTE:The catalytic converter remains in the vehicle. Item 13 : Coolant distribution connection | -
Remove the camshafts. For additional information, refer to: Nockenwellen (303-01 Motor - 1.6L Duratec-16V Ti-VCT (Sigma), In-vehicle Repair). | | -
Using the special tool, remove the coolant hose from the coolant outlet connection. | | -
Detach the coolant distribution connection from the cylinder head. | | -
Remove the rear timing belt cover. | Item 14 : Intake manifold | -
Detach the fuel supply line bracket from the intake manifold. | | -
Detach the fuel supply line from the fuel rail. For additional information, refer to: Schnellkupplung (310-00 Kraftstoffsystem - Allgemeine Informationen, General Procedures). | | -
Remove the lower bolts from the intake manifold. | | -
Detach the engine wiring harness connector. | Item 15 : Cylinder head | -
WARNING:Only remove the cylinder head bolts once the cylinder head temperature has dropped below 30 degrees C. Remove the cylinder head bolts in the sequence indicated using the special tool. | Installation Details Item 15 : Cylinder head | -
WARNING:The new cylinder head gasket must be of the same thickness as the original gasket (holes or teeth). NOTE:Install a new cylinder head gasket. NOTE:Position the cylinder head on the two guide sleeves. Using the special tool, install the cylinder head. - Tighten the bolts in the sequence shown, in three stages.
| Item 14 : Intake manifold | -
Install the lower bolts of the intake manifold. | | -
Connect the engine wiring harness connector. | | -
Attach the fuel supply line to the fuel rail. For additional information, refer to: Schnellkupplung (310-00 Kraftstoffsystem - Allgemeine Informationen, General Procedures). | | -
Attach the fuel supply line bracket to the intake manifold. | Item 13 : Coolant distribution connection | -
NOTE:Install a new coolant distribution connection gasket. Attach the coolant distribution connection to the cylinder head. | | -
Using the special tool, connect the coolant hose to the coolant outlet connection. | | -
Install the rear timing belt cover. | | -
Install the camshafts. For additional information, refer to: Nockenwellen (303-01 Motor - 1.6L Duratec-16V Ti-VCT (Sigma), In-vehicle Repair). | Item 4 : Flexible exhaust pipe nuts. | -
NOTE:Install a new flange gasket. Coat the flexible exhaust pipe nuts with grease and install. | | -
Remove the support sleeves. | Item 3 : Exhaust manifold bolt and nuts | -
NOTE:Install a new exhaust manifold gasket. Coat the bolt and nuts with grease and install. | |