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Crankshaft Front Seal > < Valve Clearance

Focus 1999 (08.1998-12.2004)

Engine - 1.8L Diesel - Valve Cover Focus 1999 (08/1998-12/2004)
In-vehicle Repair

Removal

All vehicles
  1. Remove the engine upper cover.

  1. NOTE:
    NOTE:Make a note of the position of the charge air cooler outlet hose retaining clamp.
    Remove the charge air cooler outlet pipe.
    1. Remove and discard the charge air cooler outlet hose retaining clamp.
    1. Detach the charge air cooler outlet hose retaining clamp.
    1. Remove the charge air cooler outlet pipe retaining nuts.

  1. NOTE:
    NOTE:Make a note of the position of the turbocharger outlet hose and clamps.
    Remove the charge air cooler intake pipe.
    1. Remove and discard the charge air cooler intake hose retaining clamp.
    1. Remove and discard the turbocharger outlet hose and clamps.
    1. Remove the charge air cooler intake pipe retaining nuts.

  1. Disconnect the positive crankcase ventilation (PVC) hoses from the valve cover.
Vehicles with common rail fuel injection
  1. Disconnect the camshaft position (CMP) sensor electrical connector.
All vehicles
  1. Remove the valve cover.

Installation

All vehicles
  1. NOTE:
    NOTE:Install a new valve cover gasket if necessary.
    Install the valve cover.
    • Lubricate the valve cover gasket with clean engine oil before installation.
Vehicles with common rail fuel injection
  1. Connect the camshaft position (CMP) sensor electrical connector.
All vehicles
  1. Connect the positive crankcase ventilation (PVC) hoses to the valve cover.
Vehicles built up to 05/1999
  1. NOTE:
    NOTE:Install a new charge air cooler resonator.
    Install the charge air cooler resonator.

  1. NOTE:
    NOTE:Install a new charge air cooler resonator hose.
    Install the charge air cooler resonator hose.
All vehicles
  1. CAUTION:
    CAUTION:Install a new turbocharger outlet hose and clamps in the same position as removed. Faliure to follow this instruction may cause premature failure of adjacent components.
    Install the turbocharger outlet hose to the charge air cooler intake pipe.

  1. CAUTION:
    CAUTION:The charge air cooler intake hose retaining clamp must be installed in the same position as removed. Failure to follow this instruction may cause premature failure of adjacent components.
    NOTE:
    NOTE:Make sure that the inside of the charge air cooler intake hose is clean and free from any oil residue, as this will reduce the installation grip of the hose to the charge air cooler.
    NOTE:
    NOTE:Install a new charge air cooler intake hose retaining clamp.
    Install the charge air cooler intake pipe.
    • Clean the inside of the charge air cooler intake hose.
    • Install a new charge air cooler intake hose retaining clamp in the same position as when removed.

  1. CAUTION:
    CAUTION:The charge air cooler to intake manifold hose retaining clamp must be installed in the same position as removed. Failure to follow this instruction may cause premature failure of adjacent components.
    Install the charge air cooler to intake manifold hose and retaining clamp.
    • Install the hose retaining clamp in the same position as when removed.

  1. CAUTION:
    CAUTION:The charge air cooler outlet hose retaining clamp must be installed in the same position as removed. Failure to follow this instruction may cause premature failure of adjacent components.
    NOTE:
    NOTE:Make sure that the inside of the charge air cooler outlet hose is clean and free from any oil residue, as this will reduce the installation grip of the hose to the charge air cooler.
    NOTE:
    NOTE:Install a new charge air cooler outlet hose retaining clamp.
    Install the charge air cooler outlet pipe.
    • Clean the inside of the charge air cooler outlet hose.
    • Install the charge air cooler outlet hose retaining clamp in the same position as when removed.

  1. Install the engine upper cover.

Crankshaft Front Seal > < Valve Clearance