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In-vehicle Repair|Oil Pan > < Exhaust Manifold

Focus 1999 (08.1998-12.2004)

Engine - 1.4L/1.6L - Cylinder Head Focus 1999 (08/1998-12/2004)
In-vehicle Repair

Special Tool(s)

Angle gauge

303-174 (21540)

Socket, cylinder head bolts

303-392 (21167)
General Equipment
Trolley jack
Materials
Name
Specification
Coolant
WSS-M97B44-D 
Sealant, camshaft bearing cap on cylinder head
WSK-M2G348-A2 
Engine Oil
WSS-M2C912-A1 

Removal

  1. Standard preparatory measures
    • If necessary, use Special Tool 303-397 to install and remove coolant and ventilation hoses.
    • Open coolant expansion tank.
  1. Release the pressure from the fuel system. For additional information, refer to:
    Fuel System Pressure Release (310-00A Fuel System - General Information, General Procedures),
    Fuel Line Evacuation Without Using Recovery Equipment (310-00B Fuel System - General Information - Liquified Petroleum Gas (LPG), General Procedures),
    Fuel Line Evacuation Using Recovery Equipment (310-00B Fuel System - General Information - Liquified Petroleum Gas (LPG), General Procedures),
    Fuel Line Evacuation Without Using Recovery Equipment (310-00C Fuel System - General Information - Liquified Petroleum Gas (LPG), General Procedures),
    Fuel Line Evacuation Using Recovery Equipment (310-00C Fuel System - General Information - Liquified Petroleum Gas (LPG), General Procedures).
  1. Disconnect the battery ground cable.
    For additional information, refer to: Battery Disconnect (414-01 Battery, Mounting and Cables, General Procedures).

  1. NOTE:
    NOTE:Collect the coolant and re-use as required.
    Drain the coolant (shown from below).
    • Unscrew and remove the drain plug.
    • Reinstall the drain plug after draining.

  1. Remove engine ground cable and exhaust manifold heat shield.
    1. Engine ground cable.
    1. Exhaust manifold heat shield (three bolts).

  1. Detach the exhaust manifold (shown from below) and tie it in place.
    • Remove the gasket.

  1. Remove the air filter and intake hose.
    1. Intake hose.
    1. Detach the mass air flow sensor (MAF) connector.
    • Detach the crankcase ventilation hose from the cylinder head.

  1. Detach the accelerator cable.
    1. Pull off the clip.
    1. Remove the cable from the bracket.

  1. Pull off the crankcase ventilation hose.

  1. Separate the engine wiring loom multiplug and disconnect the plug for the camshaft position (CMP) sensor.

  1. Detach the connector.
    1. Ignition coil (EI).
    1. Condenser.

  1. Detach the hoses and unclip the connector.
    1. Carbon canister solenoid valve vacuum hose.
    1. Knock sensor (KS) plug.
    1. Brake servo vacuum hose.

  1. Remove coolant and heater hoses.
    1. Coolant expansion tank hose.
    1. Heater hose.
    1. Coolant hose.

  1. Detach the carbon canister vacuum pipe.

  1. WARNING:
    WARNING:Escaping fuel. Observe the safety regulations for working with fuel.
    NOTE:
    NOTE:The fuel feed line unions are white or are identified with a white ring. The fuel return line unions are red or are identified with a red ring.
    Disconnect the fuel pipes.
  1. Remove the camshafts.
    For additional information, refer to: Camshafts (303-01A Engine - 1.4L/1.6L, In-vehicle Repair).

  1. Remove the three lower inlet manifold bolts from the cylinder block and detach the oil dipstick tube.
    • Unclip the knock sensor (KS) plug from the oil dipstick tube.

  1. CAUTION:
    CAUTION:Before detaching, allow the cylinder head to cool to below 30°C.
    CAUTION:
    CAUTION:Place the cylinder head on a soft support.
    NOTE:
    NOTE:Slackening sequence.
    Detach the cylinder head.
    • Remove the cylinder head bolts using the special tool.

Installation
  1. NOTE:
    NOTE:Tightening sequence.
    NOTE:
    NOTE:The cylinder head is placed into two guide sleeves.
    NOTE:
    NOTE:The cylinder head bolts can be re-used.
    Attach the cylinder head.
    • Make sure all mating faces are clean.
    • Fit a new cylinder head gasket.
    • Install the cylinder head, tightening in four stages in the sequence indicated.
    • Stage 1: 15 Nm.
    • Stage 2: 30 Nm.
    • Stage 3 using Special Tool 303-174: 90 degrees.

  1. Install the three lower inlet manifold bolts and attach the oil dipstick tube.
    • Clip the knock sensor (KS) plug to the oil dipstick tube.

  1. Connect the fuel pipes.
  1. Install the camshafts.
    For additional information, refer to: Camshafts (303-01A Engine - 1.4L/1.6L, In-vehicle Repair).

  1. Attach the carbon canister vacuum pipe.

  1. Attach the coolant hoses and heater hoses using Special Tool 303-622.
    1. Coolant expansion tank hose.
    1. Heater hose.
    1. Coolant hose.

  1. Attach hoses and clip on the connector.
    1. Carbon canister solenoid valve vacuum hose.
    1. Knock sensor (KS) plug.
    1. Brake servo vacuum hose.

  1. Attach connector.
    1. Ignition coil (EI).
    1. Condenser.

  1. Connect the engine wiring loom multiplug and the plug for the camshaft position (CMP) sensor.

  1. Connect the PCV hose.

  1. Attach the accelerator cable.
    1. Push on the clip.
    1. Fit the cable into the bracket.

  1. Attach the air filter with intake hose.
    1. Intake hose.
    1. Mass air flow sensor (MAF) connector.
    • Attach the crankcase ventilation hose to the cylinder head cover.

  1. NOTE:
    NOTE:Use a new exhaust manifold gasket.
    Attach the exhaust manifold (shown from below).

  1. Attach the exhaust manifold heat shield and the engine ground cable.
    1. Exhaust manifold heat shield (three bolts).
    1. Engine ground cable.
  1. Standard finishing operations.
    • Change the oil (and the oil filter).
    • Connect the battery negative lead.
      For additional information, refer to: Battery Disconnect (414-01 Battery, Mounting and Cables, General Procedures).
    • Fill the cooling system.
      For additional information, refer to: Cooling System Draining, Filling and Bleeding (303-03 Engine Cooling, General Procedures).
    • Bleed the fuel system.
    • Check the engine and the cooling system for leaks (visual inspection).

In-vehicle Repair|Oil Pan > < Exhaust Manifold