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In-vehicle Repair|Oil Pan > < Exhaust Manifold

Focus 1999 (08.1998-12.2004)

Engine - 2.0L Duratec-ST (Zetec) - Cylinder Head Focus 1999 (08/1998-12/2004)
In-vehicle Repair

Special Tool(s)

Socket, Cylinder Head Bolt

303-392 (21-167)

Remover/Installer, Hose Clamp

303-397 (24-003)
General Equipment
Spatula
Materials
Name
Specification
Sealer remover
WSK-M2G348-A4 
Engine oil
WSS-M2C912-A1 

Removal

  1. Disconnect the battery. For additional information, refer to Section  414-01 Battery, Mounting and Cables.
  1. Release the fuel system pressure. For additional information, refer to Section  310-00A Fuel System - General Information / 310-00B Fuel System - General Information / 310-00C Fuel System - General Information.
  1. WARNING:
    WARNING:To prevent the risk of scalding, place a thick cloth over the filler cap before opening the cooling circuit. Failure to do so may result in personal injury.
    Release the coolant system pressure.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Drain the coolant from the radiator.
    • Allow the coolant to drain into a suitable container.
    • Install the radiator drain plug after draining the coolant.

  1. Disconnect the oil pressure switch electrical connector.

  1. Remove the intake manifold lower retaining bolt.
  1. Remove the accessory drive belt. For additional information, refer to Section  303-05 Accessory Drive.
  1. Lower the vehicle.
  1. Remove the air cleaner. For additional information, refer to Section  303-12 Intake Air Distribution and Filtering.

  1. Detach the brake booster pipe from the intake manifold.
    • Release the quick release coupling and detach the brake booster pipe.

  1. Detach the accelerator cable from the throttle body.

  1. Disconnect the vacuum hoses from the intake manifold.

  1. Disconnect the fuel injector wiring harness electrical connectors.

  1. Disconnect the camshaft position (CMP) sensor electrical connector.

  1. WARNING:
    WARNING:Escaping fuel. Observe the safety regulations for working with fuel.
    Disconnect the fuel lines.

  1. Disconnect the ground cable from the lifting eye.
  1. Remove the exhaust manifold.
    For additional information, refer to Exhaust Manifold in this section.

  1. Detach the thermostat housing.

  1. Detach the power steering pipe bracket from the cylinder head.

  1. Detach the power steering pump bracket from the cylinder head and cylinder block.

  1. Detach the generator.
    1. Loosen the bolt.
    1. Remove the bolt.

  1. Disconnect the wiring harness from the electronic ignition (EI) coil and from the engine coolant temperature (ECT) sensor.

  1. Remove the upper bolt from the generator bracket.
  1. Remove the camshafts.
    For additional information, refer to Camshafts in this section.

  1. CAUTION:
    CAUTION:Cylinder head bolts can only be used twice, mark the bolts to indicate usage.
    CAUTION:
    CAUTION:The cylinder head must be cooled to ambient temperature.
    NOTE:
    NOTE:Evenly loosen the cylinder head bolts in the sequence shown.
    Remove the cylinder head bolts.
  1. Remove the cylinder head.

Installation

All vehicles
  1. Remove gasket residue withsealer removerand aspatula.
    • Thoroughly clean the threaded holes of the cylinder head bolts.
  1. Check the cylinder head deformation. For additional information, refer to Section  303-00 Engine System - General Information.

  1. Make up two locating studs as shown.

  1. NOTE:
    NOTE:Install a new cylinder head gasket.
    Install the cylinder head gasket.
    1. Position the cylinder head gasket.
    1. Insert the fabricated locating studs.
    1. Check that the locating studs are seated correctly.
  1. Install the cylinder head.

  1. CAUTION:
    CAUTION:Do not retighten the cylinder head bolts.
    Tighten the cylinder head bolts in three stages in the sequence indicated.
    • Stage 1: 20 Nm.
    • Stage 2: 40 Nm.
    • Stage 3: 90 degrees.
  1. NOTE:
    NOTE:Coat the valve tappets with clean engine oil before installation.
    Install the valve tappets.
  1. Install the camshafts.
    For additional information, refer to Camshafts in this section.
  1. Check the valve clearance and if necessary adjust.
    For additional information, refer to Valve Clearance Adjustment in this section.
  1. Lower the vehicle.

  1. Attach the power steering pump bracket to the cylinder head and cylinder block.

  1. Install the generator bracket bolt.

  1. Connect the wiring harness to the electronic ignition (EI) coil and to the engine coolant temperature (ECT) sensor.

  1. Attach the generator.

  1. Attach the power steering pipe bracket to the cylinder head.

  1. NOTE:
    NOTE:Install a new thermostat housing gasket.
    Attach the thermostat housing.

  1. Attach the fuel lines.

  1. Connect the camshaft position (CMP) sensor connector.

  1. Connect the fuel injector wiring harness electrical connectors.

  1. Attach the accelerator cable and the speed control cable (if equipped) to the throttle body.

  1. Attach the vacuum hoses to the intake manifold.

  1. Attach the brake booster pipe to the intake manifold.
  1. Install the exhaust manifold.
    For additional information, refer to Exhaust Manifold in this section.

  1. Install the intake manifold lower retaining bolt.

  1. Connect the oil pressure switch electrical connector.
  1. NOTE:
    NOTE:Install a new oil filter.
    Drain theengine oil.
  1. Lower the vehicle.
  1. Install the air cleaner. For additional information, refer to Section  303-12 Intake Air Distribution and Filtering.
  1. Fill the engine withengine oil
  1. Fill and bleed the cooling system. For additional information, refer to Section  303-03 Engine Cooling.
  1. Connect the battery ground cable. For additional information, refer to Section  414-01 Battery, Mounting and Cables.
Vehicles with front and rear power windows
  1. Initialize the door window motors. For additional information, refer to Section  501-11 Glass, Frames and Mechanisms.

In-vehicle Repair|Oil Pan > < Exhaust Manifold