Cylinder Head

Removal

1. Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).
   

1. Refer to: Fuel System Pressure Release (310-00B Fuel System - General Information - 1.6L EcoBoost (132kW/180PS) - Sigma, General Procedures).
   

1. Remove the following items:
   1. Refer to: Turbocharger (303-04C Fuel Charging and Controls - Turbocharger - 1.6L EcoBoost (132kW/180PS) - Sigma, Removal and Installation).
      
   2. Refer to: Camshafts (303-01A Engine - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, Removal and Installation).
      
   3. Refer to: Intake Manifold (303-01A Engine - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, Removal and Installation).
      

1. General Equipment : Hose Clamp Remover/Installer

1. General Equipment : Hose Clamp Remover/Installer

1. NOTE: If the camshafts and valve tappets are to be reused, mark the location of the valve tappets to make sure they are assembled in their original positions.

   NOTE: The number on the valve tappets only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 0.1437  in ( 3.65  mm).

1. Install new components as necessary.
   

1. NOTE: Make sure that the cylinder head is at ambient air temperature before removing the cylinder head bolts.

1. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion.
   Refer to: Cylinder Head Distortion (303-00 Engine System - General Information, General Procedures).
   Refer to: Cylinder Block Distortion (303-00 Engine System - General Information, General Procedures).
   

Installation

1. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.

   NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.

   NOTE:

   Material : Motorcraft® Metal Surface Prep / ZC-31-A

1. NOTE: Make sure that new bolts are installed.

   NOTE: Make sure that no fluids are present in the cylinder head bolt threaded bores.

   Torque :
     Stage 1:  5 Nm
     Stage 2:  15 Nm
     Stage 3:  35 Nm
     Stage 4:  90°
     Stage 5:  Tighten an additional 90°

1. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

1. General Equipment : Hose Clamp Remover/Installer

1. General Equipment : Hose Clamp Remover/Installer

1. Install the following items:
   1. Refer to: Intake Manifold (303-01A Engine - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, Removal and Installation).
      
   2. Refer to: Camshafts (303-01A Engine - 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, Removal and Installation).
      
   3. Refer to: Turbocharger (303-04C Fuel Charging and Controls - Turbocharger - 1.6L EcoBoost (132kW/180PS) - Sigma, Removal and Installation).
      

1. General Equipment : Oil Drain Equipment
   General Equipment : Strap Wrench

1. General Equipment : Oil Drain Equipment
   Torque : 28 Nm

1. Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
   Torque : 14.5 Nm

1. Fill the engine with clean engine oil.
   Material : Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

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