Ford Mondeo cylinder head cover removal and refitting - is a part of Ford Mondeo repair manuals: Engines. This part contains the detailed description of engine repair procedures and engine diagrams for Ford Mondeo with four-cylinder petrol engines, including special/limited editions (1597cc, 1796cc, 1988cc), Diesel and V6 engines.
Ford Mondeo cylinder head cover removal and refitting:
- unplug the two electrical connectors and disconnect the vacuum hose (where fitted), then remove the air cleaner assembly cover with the air mass meter, the resonator and the plenum chamber;
- disconnect the accelerator cable from the throttle linkage;
- where fitted, disconnect also the cruise control actuator cable (see Ford Mondeo repair manuals: Electrical Equipment);
- remove the timing belt upper cover (see Ford Mondeo repair manuals: Engines);
- disconnect the crankcase breather hose from the cylinder head cover union;
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- unplug the HT leads from the spark plugs and withdraw them, unclipping the leads from the cover;
- working progressively, unscrew the cylinder head cover retaining bolts, noting the spacer sleeve and rubber seal at each, then withdraw the cover;
- discard the cover gasket; this must be renewed whenever it is disturbed;
- check that the sealing faces are undamaged, and that the rubber seal at each retaining bolt is serviceable; renew any worn or damaged seals;
- on refitting, clean the cover and cylinder head gasket faces carefully, then fit a new gasket to the cover, ensuring that it locates correctly in the cover grooves;
- refit the cover to the cylinder head, then insert the rubber seal and spacer sleeve at each bolt location;
- start all bolts finger-tight, ensuring that the gasket remains seated in its groove;
- working in a diagonal sequence from the centre outwards, and in two stages (see Ford Mondeo repair manuals: Engines - Specifications), tighten the cover bolts to the specified torque wrench setting;
- refit the HT leads, clipping them into place so that they are correctly routed; each is numbered, and can also be identified by the numbering on its respective coil terminal;
- reconnect the crankcase breather hose, and refit the timing belt upper cover;
- reconnect and adjust the accelerator cable, then refit the air cleaner assembly cover with the air mass meter, the resonator and the plenum chamber.
from Ford Mondeo repair manuals
