Engine 2.0L Zetec 2000 Escort
Special Tool(s) Disconnect Tool 3/8 Inch Fuel Line
310-D004 (D87L-9280-A) or equivalent
Disconnect Tool 1/2 Inch Fuel Line
310-D005 (D87L-9280-B) or equivalent
Disconnect the battery ground cable (14301).
WARNING: Fuel supply lines will remain pressurized for long periods of time after engine shut down. This pressure must be relieved before disconnecting any fuel lines or fuel system components.
Relieve the fuel system pressure.
Remove the engine air cleaner outlet tube.
Remove the timing belt.
Remove the vacuum hoses at the:
positive crankcase ventilation (PCV) valve (6A666).
Throttle body (9E926).
Intake manifold (9424).
Fuel pressure sensor.
Disconnect the fuel charging wiring (9D930) electrical connectors at main engine connector.
Disconnect the crankshaft position (CKP) sensor electrical connector.
Disconnect the fuel line.
Remove the power steering pump (3A674) and bracket as an assembly.
Remove the generator (GEN).
Remove the oil level indicator tube (6754).
Disconnect the heater hoses.
Lower the vehicle.
Disconnect the upper radiator hose (8260) from the thermostat housing water hose connection.
Remove the camshafts (6250).
Remove the ignition coil (12029) and bracket.
Remove the water thermostat housing.
Disconnect the knock sensor electrical connector.
Remove the generator bracket-to-cylinder head bolt.
Remove the bolts and the cylinder head (6049).
Remove the cylinder head gasket and discard.
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 be ignited, resulting in possible personal injury.
CAUTION: Do not use abrasive grinding discs to remove gasket material; use only plastic manual scrapers. Do not scratch or gouge the aluminum sealing surfaces.
Clean all gasket material from the mating surfaces on the cylinder head and cylinder block. Clean out the bolt holes in the cylinder block. Inspect the cylinder head for flatness. For additional information, refer to Section 303-00.
Install a new head gasket on the cylinder block.
CAUTION: Do not attempt to install the cylinder head assembly without assistance. Installation of the cylinder head assembly requires two people or possible injury may occur.
CAUTION: The bolts are torque-to-yield and must be replaced or engine damage may occur.
Tighten the bolts in three stages in the sequence shown.
Stage 1: Tighten the bolts to 15-25 Nm (12-18 lb-ft).
Stage 2: Tighten the bolts to 35-45 Nm (26-33 lb-ft).
Stage 3: Tighten the bolts an additional 105 degrees.
Install the generator bracket-to-cylinder head bolt.
Tighten to 20 Nm (15 lb-ft).
Connect the knock sensor electrical connector.
Install the thermostat housing.
Install the ignition coil and bracket.
Install the camshafts.
Connect the upper radiator hose.
Raise and support the vehicle.
Install the heater hoses.
Install the generator and bracket assembly.
Install the power steering pump and bracket assembly.
Connect the fuel lines.
Connect the crankshaft sensor electrical connector.
Connect the fuel charging wiring connectors.
Connect the vacuum hoses at the positive crankcase ventilation (PCV) valve, throttle body, intake manifold and fuel pressure sensor.
Install the engine oil level indicator tube and bolt.
Install new spark plugs.
Install the air cleaner outlet tube.
Drain the engine oil and install a new oil filter.
Fill the crankcase with Super Premium 5W30 SAE Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C158-G.
Connect the negative battery cable.
Fill and bleed the power steering system.
Fill the engine cooling system.
Charge the A/C system.
Run the engine and inspect for leaks.
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Saturday, January 8th, 2011 AT 11:32 PM