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Focus 1999 (08.1998-12.2004)

Engine - 2.0L Duratec-ST (Zetec) - Cylinder Head Focus 1999 (08/1998-12/2004)
Disassembly and Assembly of Subassemblies

Special Tool(s)

Compressor, Valve Spring

303-300 (T87C-6565-A)

Compressor, Valve Spring

303-350 (T89P-6565-A)

Remover, Valve Stem Oil Seal

303-468 (T94P-6510-AH)

Installer, Valve Stem Oil Seal

303-470 (T94P-6510-CH)

Slide Hammer

307-005 (T59L-100-B)
Materials
Name
Specification
Engine Oil - 5W-30
WSS-M2C153-G 

Disassembly
  1. Disconnect the throttle position (TP) sensor electrical connector (air cleaner shown removed for clarity).

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

  1. Disconnect the idle air control (IAC) valve electrical connector (air cleaner shown removed for clarity).

  1. Remove the CMP.

  1. Remove the electronic ignition (EI) coil pack.

  1. Disconnect the vacuum line from the fuel pressure sensor.

  1. Disconnect the vacuum line from the fuel pulse damper.

  1. Remove the fuel injection supply manifold.

  1. Separate the two sections of the intake manifold.

  1. Remove the bracket.

  1. Remove the intake manifold inner section locknut and bolts (intake manifold shown removed for clarity).
    • Discard the locknut.
  1. Remove the intake manifold inner section.

  1. Remove the timing belt tensioner and idler pulley.

  1. Remove the inner timing belt cover.

  1. Remove the rear lifting eye.

  1. Remove the front lifting eye.

  1. Using the special tools, compress the valve spring and remove the valve spring retainer keys, the valve spring retainers, and the valve springs.
    • Remove the special tools.
  1. Inspect the valve spring, valve spring retainer and valve spring retainer key. Install new parts as necessary.

  1. NOTE:
    NOTE:Mark each valve if the original valves are to be used.
    Remove the valves.

  1. Using the special tools, remove and discard the valve stem seals.
  1. Inspect the valves.
    For additional information, refer to: Valve Stem Diameter (303-00 Engine System - General Information, General Procedures).
    Install new parts as necessary.

Assembly
  1. NOTE:
    NOTE:If installing the original valves, make sure the valves are installed in the position from which they were removed. Coat the valve stems with 5W-30 Engine Oil or equivalent meeting Ford specification WSS-M2C153-G.
    Install the valves.

  1. NOTE:
    NOTE:Use the seal protector provided with the replacement kit to prevent damage to the valve stem seals.
    Lubricate valve and guides with engine oil and using the special tool install the valve stem seals onto the cylinder head valve guides.
  1. Place the valve spring in position over the valve and install the valve spring retainer.

  1. Using the special tools, compress the valve spring and install the valve spring retainer keys.
    • Remove the special tools.

  1. Install the front lifting eye.

  1. Install the rear lifting eye.

  1. Install the inner timing belt cover.

  1. Install the timing belt tensioner and the idler pulley.
  1. NOTE:
    NOTE:Clean and inspect the intake manifold gasket. Install a new intake manifold gasket if necessary.
    Install the intake manifold inner section.

  1. NOTE:
    NOTE:Install a new intake manifold locknut.
    Install the intake manifold inner section locknut and bolts (intake manifold shown removed for clarity).

  1. Install the bracket.

  1. Assemble the two sections of the intake manifold.

  1. Install the fuel injection supply manifold.

  1. Connect the vacuum line yo the fuel pulse damper.

  1. Connect the vacuum line to the fuel pressure sensor.

  1. Install the electronic ignition (EI) coil pack.

  1. Install the camshaft position (CMP) sensor.

  1. Connect the idle air control (IAC) valve electrical connector (air cleaner shown removed for clarity).

  1. Connect the CMP electrical connector.

  1. Connect the throttle position (TP) sensor electrical connector (air cleaner shown removed for clarity).

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