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Assembly|Installation > < Cylinder Head

Focus 1999 (08.1998-12.2004)

Engine - 2.0L Duratec-ST (Zetec) - Engine Focus 1999 (08/1998-12/2004)
Assembly

Special Tool(s)

Installer, Crankshaft Rear Oil Seal

303-291 (21-141)

Timing Plate, Camshaft Alignment

303-376 (21-162B)

Timing Pin, Crankshaft TDC

303-574 (21-163)

Installer, Timing Cover Oil Seal

303-039 (21-009B)

Locking Tool, Flywheel

303-254 (21-135)
General Equipment
Steel straight edge
Materials
Name
Specification
Sealer
WSK-M4G320-A 
Sealer
WSK-M2G348-A5 
Sealer
WSS-M4G323-A7 
Engine oil
WSS-M2C912-A1 
Silicone grease
A960-M1C171-AA 
  1. NOTE:
    NOTE:Install a new crankshaft rear oil seal carrier gasket.
    NOTE:
    NOTE:Do not fully tighten the crankshaft rear oil seal carrier retaining bolts at this stage.
    Install the rear oil seal carrier.

  1. Install the crankshaft position (CKP) sensor and mounting bracket.

  1. CAUTION:
    CAUTION:The oil seal must be inserted as far as its stop onto the special tool.
    Insert a new crankshaft rear oil seal into the special tool.
    • For correct installation lay the special tool on a vice and use the handle of a hammer to press in the oil seal.
    1. Incorrect installation.
    1. Correct installation.

  1. NOTE:
    NOTE:Install a new crankshaft rear oil seal.
    Using the special tool and two old flywheel bolts, install the crankshaft rear oil seal.

  1. Align the crankshaft rear oil seal carrier so that the sealing surface of the oil seal carrier is 0.3 mm - 0.8 mm below the cylinder block and tighten the retaining bolts.

  1. Remove the special tool.

  1. NOTE:
    NOTE:Install a new oil pump gasket.
    NOTE:
    NOTE:Do not fully tighten the oil pump retaining bolts at this stage.
    Install the oil pump.

  1. Align the oil pump on both sides so that the mating face is between 0.3 mm - 0.8 mm above the lower edge of the cylinder block.

  1. Tighten the oil pump retaining bolts.

  1. NOTE:
    NOTE:Install the lower crankcase within 10 minutes of applying the sealer.
    Apply a 4 mm bead of sealer to the areas as shown.

  1. NOTE:
    NOTE:If the permissible amounts for protrusion or gap are exceeded, install shims as described in the following steps.
    Align the lower crankcase.
    • Using a steel straight edge, align the lower crankcase so that the cylinder block and the lower crankcase are flush, or do not exceed 0.10 mm protrusion to 0.25 mm gap.
    • Position the lower crankcase with a new gasket and tighten the bolts finger tight.

  1. Install lower crankcase shims as necessary.
    • with a gap of 0.26 - 0.50 mm, install a 0.25 mm shim.
    • with a gap of 0.51 - 0.75 mm, install a 0.50 mm shim.

  1. NOTE:
    NOTE:Install a new oil pump pickup tube gasket.
    Install the lower crankcase.
    1. Tighten the bolts and check the alignment as described in the previous step, correct as necessary.
    1. Install the oil pump pickup tube.

  1. CAUTION:
    CAUTION:The lower crankcase may be damaged if sealer enters the blind holes.
    Install ten M6 x 20 mm studs into the blind holes as shown.

  1. NOTE:
    NOTE:Attach the oil pan within ten minutes of applying the sealer.
    Apply a 3 mm thick bead of sealer on to the oil pan mating face.

  1. NOTE:
    NOTE:The oil pan must not be removed once it comes into contact with the lower crankcase housing.
    Install the oil pan.
    • Remove the studs.
    • Install and tighten the bolts in the sequence shown in two stages.
    • Stage 1: 6 Nm.
    • Stage 2: 10 Nm.

  1. NOTE:
    NOTE:Install new flywheel retaining bolts.
    NOTE:
    NOTE:Remove any residual thread-locking compound from the threaded bores.
    Using the special tool, install the flywheel.
  1. Install the clutch disc and pressure plate. For additional information, refer to Section  303-01A Engine / 303-01B Engine / 303-01C Engine / 303-01G Engine.

  1. NOTE:
    NOTE:Install a new cylinder head gasket.
    NOTE:
    NOTE:Install the cylinder head bolts free of oil.
    NOTE:
    NOTE:Tighten the cylinder head bolts in three stages in the indicated sequence.
    Install the cylinder head.
    • Stage 1: 20 Nm.
    • Stage 2: 40 Nm.
    • Stage 3: 90 degrees.
  1. Lubricate the valve tappets with engine oil and install them in the correct order.
  1. Turn the crankshaft to approximately 60 degrees BTDC.
  1. Lay the camshafts in place with none of the cams at full lift.
  1. Coat the camshafts and camshaft bearing caps with engine oil and insert them.

  1. NOTE:
    NOTE:Working in several stages, evenly tighten the camshaft bearing cap bolts in the indicated sequence, half a turn at a time.
    Install the camshafts.
    • Tighten the bolts in the sequence shown.

  1. NOTE:
    NOTE:Install a new oil feed flange oil seal.
    Apply sealer to the marked areas on the oil feed flange.

  1. Install the oil feed flange.
  1. Check the valve clearance and if necessary adjust.
    For additional information, refer to Valve Clearance Adjustment in this section.

  1. Install the exhaust camshaft oil seal.
    • Lubricate the camshaft and the seal lip of the oil seal with engine oil.
    • Draw in the new oil seals using the special tool, a washer and an M10 x 70 bolt.

  1. Turn the crankshaft to TDC on cylinder number 1.

  1. NOTE:
    NOTE:Cylinders 1 and 4 are at TDC when the Woodruff key points towards the piston.
    Remove the blanking plug and align the crankshaft at TDC using the special tool.

  1. Turn the camshafts to ignition point on cylinder number 1 and insert the special tool into the camshafts.

  1. NOTE:
    NOTE:Do not fully tighten the camshaft pulley retaining bolts at this stage.
    Install the camshaft pulleys.

  1. Install a new water pump gasket by bending over the tabs.
    1. Lay the gasket in place.
    1. Secure the gasket by bending over the tabs.

  1. CAUTION:
    CAUTION:Do not kink the timing belt (do not bend the timing belt by more than a diameter of 35 mm).
    CAUTION:
    CAUTION:Do not rotate the crankshaft; check that it is still resting against the timing pin.
    NOTE:
    NOTE:The lug of the timing belt tensioner must not be hooked into the sheet metal cover during timing belt installation.
    Position a new timing belt.
    1. Slide the crankshaft timing pulley with a thrust washer onto the crankshaft.
    1. Attach the water pump.
    1. Attach the upper idler pulley.
    1. Starting from the crankshaft timing belt pulley and working counterclockwise, position the timing belt in place while keeping it under tension.
    1. Attach the timing belt tensioner and tighten the bolt five turns.

  1. CAUTION:
    CAUTION:Incorrect timing belt tension will cause incorrect valve timing.
    Pre tension the timing belt.
    1. Rotate the tensioner locating tab counterclockwise and insert the locating tab into the slot in the rear timing cover.
    1. Position the hexagonal key slot in the tensioner adjusting washer to the 4 o'clock position.
    1. Using a 6 mm hexagonal key tighten the bolt enough to seat the tensioner firmly against the rear timing cover, but still allow the tensioner adjusting washer to be rotated .

  1. CAUTION:
    CAUTION:Tension the timing belt, working counterclockwise.
    Using the hexagonal key, rotate the adjusting washer counterclockwise until the notch in the pointer is centered over the index line on the locating tab (the pointer will move clockwise during adjustment).

  1. While holding the adjusting washer in position, tighten the bolt.

  1. NOTE:
    NOTE:Hold the camshafts by the hexagon with an open ended wrench to prevent them from rotating.
    Tighten the camshaft pulley retaining bolts.

  1. NOTE:
    NOTE:Hold the camshaft by the hexagon with an open ended wrench to prevent it from rotating.
    Install the intake camshaft pulley blanking plug.

  1. Remove special tool.

  1. Remove special tool.
  1. NOTE:
    NOTE:Turn the engine two turns in the normal direction of rotation by the crankshaft.
    Check the valve timing by inserting the special tools and correct the alignment as necessary.
    • Screw in Special Tool 303-574 and make sure that the crankshaft is resting against the special tool.
    • Insert Special Tool 303-376 into the camshafts. If necessary loosen the timing pulleys and correct the camshaft alignment.
    • Remove the special tools.

  1. Install the blanking plug.
  1. Check the valve clearance and if necessary adjust.
    For additional information, refer to Valve Clearance Adjustment in this section.

  1. Install the valve cover.

  1. CAUTION:
    CAUTION:Use a blunt object (a plastic cable tie) to apply the silicone grease to avoid damaging the spark plug electrical connectors.
    CAUTION:
    CAUTION:Push on the spark plug electrical connectors, keeping them in line with the spark plugs.
    NOTE:
    NOTE:Coat the inside of the spark plug electrical connectors to a depth of 5 - 10 mm with silicone grease.
    Connect the spark plug electrical connectors.
    • Push on the spark plug electrical connectors until they click in place.

  1. NOTE:
    NOTE:Check the seating of the gasket on the upper timing belt cover and correct as necessary.
    Attach the timing belt covers and the belt pulleys.
    1. Lower timing belt cover.
    1. Crankshaft pulley.
    1. Upper timing belt cover.
    1. Engine front mount bracket.
    1. Drive belt idler pulley.
    1. Water pump belt pulley.

  1. Connect the positive crankcase ventilation using a new seal.
    1. Three bolts.
    1. One bolt.

  1. Attach the ancillary components on the exhaust side.
    1. Air conditioning compressor bracket.
    1. Power steering pump bracket.
    1. Power steering pump to cylinder block bracket.

  1. Install the oil cooler.
  1. Hook the engine by the engine lifting eyes onto the workshop hoist and detach it from the assembly stand.
    • Put the engine down onto the assembly stand and leave it hooked onto the workshop hoist.

  1. NOTE:
    NOTE:Coat the oil filter seal with engine oil.
    Attach the ancillary components on the intake side.
    1. Oil pressure switch.
    1. Knock sensor (KS).
    1. Attach a new oil filter.
    1. Generator bracket to cylinder block.
    1. Generator bracket to cylinder head.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Attach the generator.
    1. Tighten the bolt.
    1. Tighten the bolt.
    1. Connect the positive cable.

  1. Connect the oil pressure switch and the KS electrical connectors.

Assembly|Installation > < Cylinder Head