Mounting the Cylinder Head to the Engine Block - Endura Engine Overhaul - Episode 14.2
Assembly of the Endura engine continues with the installation of the cylinder head, intake manifold, fuel injectors, and actuators, applying torques such as 1.8 kgf·m to the manifold bolts. Vacuum hoses, sensors, and the engine mount are also organized outside the car to simplify final tightening once in place.
📋 Quick Overview / Problem & Solution
Application: Ford Endura engine, for installing the cylinder head onto the block during overhaul.
Symptom / Problem: The video documents reassembly after machining/overhaul, not diagnostic troubleshooting of a specific defect.
Procedure & Result: Manifold, actuator, side mount, cylinder head, and spark plugs are installed, with angle torquing of the cylinder head shown in detail.
⚡ Tightening Torques & Specifications
| Component | Specified Torque | Assembly Notes |
|---|---|---|
| intake manifold bolts | 18 N·m | Paulo explicitly provides the conversion: 1.8 kgf·m = 18 N·m. Used a torque wrench where accessible; some were tightened by feel due to tight space. |
| idle air control valve bolts | 10 N·m | 1.0 kgf·m × 9.81 = 9.81 N·m ≈ 10 N·m. Mentioned as specification when presenting the component. |
| alternator bracket (mounting to body/engine) | 49 N·m | 5 kgf·m × 9.81 = 49 N·m. ASR transcript slightly unclear ('fixei janê' = probably 'fixei, né'). Context is securing the alternator bracket. |
| cylinder head bolts — Stage 1 | 29 N·m | 3 kgf·m × 9.81 = 29.4 N·m ≈ 29 N·m. Tightening in three stages: 3 kgf·m → +90° → +90°, in sequence 1-2-3-4-5-6. |
| cylinder head bolts — Stages 2 & 3 (angle torque) | Angle tightening: +90° + 90° after the initial 3 kgf·m. Paulo used an extension bar to achieve sufficient leverage for the second and third stages. | |
| engine mount bolts | 62 N·m | 6.3 kgf·m × 9.81 = 61.8 N·m ≈ 62 N·m. |
| spark plugs | 7 N·m | 0.7 kgf·m × 9.81 = 6.9 N·m ≈ 7 N·m. Paulo opts for the Ford technical manual specification over NGK's recommendation. |
Video chapters
- 00:00 Let's Get Started!
- 00:01 Assembling the intake manifold
- 01:02 Idle air control valve, throttle body (TBI)
- 02:00 Results
- 03:14 Alternator Condition
- 05:26 Installing the Side Engine Mount
- 07:23 Mounting the cylinder head on the block
- 09:00 Torquing the cylinder head bolts
- 14:29 New Spark Plugs
Tools used
- Low-range Torque Wrench
- Medium-range Torque Wrench
- Medium-range Torque Wrench
Parts mentioned / replaced
- cylinder head bolts (new)
- cylinder head gasket
- NGK spark plug
- intake manifold
- exhaust manifold
- idle air control valve