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In-vehicle Repair > < Diagnosis and Testing|Engine

Focus 1999 (08.1998-12.2004)

Engine - 2.0L Duratec-ST (Zetec) - Valve Clearance Adjustment Focus 1999 (08/1998-12/2004)
General Procedures

Materials
Name
Specification
Silicone grease for spark plug connector seal
A960-M1C171-AA 
All vehicles
NOTE:
NOTE:Exchange the tappets to correct the valve clearance.
  1. Disconnect the battery ground cable.
    For additional information, refer to: Battery Disconnect (414-01 Battery, Mounting and Cables, General Procedures).

  1. NOTE:
    NOTE:Do not remove the timing belt upper cover at this stage.
    Remove the timing belt upper cover retaining bolts.

  1. Disconnect the variable camshaft timing (VCT) valve electrical connector.

  1. CAUTION:
    CAUTION:Do not pull the spark plug connectors by the ignition wires when removing them. If necessary pull off the ignition wires from the ignition coils to prevent kinking the ignition wires. Slightly twist the spark plug connectors before removing them in order to loosen the seals.
    CAUTION:
    CAUTION:Pull off the spark plug connectors in line with the spark plugs.
    NOTE:
    NOTE:Loosening sequence: from the outside to the inside, working diagonally.
    Remove the valve cover.
    1. Disconnect the spark plug electrical connectors.
    1. Disconnect the positive crankcase ventilation (PCV) hose from the valve cover.
    1. Remove the bolts.

  1. CAUTION:
    CAUTION:Only rotate the crankshaft in the normal direction of rotation.
    Rotate the crankshaft until piston No. 1 is at top dead center (TDC).

  1. NOTE:
    NOTE:Note down each cylinder number and the valve clearances measured.
    NOTE:
    NOTE:Only rotate the crankshaft in the normal direction of rotation.
    Using a suitable set of feeler gauges, measure the valve clearance.
    For additional information, refer to: Specifications (303-01D Engine - 2.0L Duratec-ST (Zetec), Specifications).
  1. NOTE:
    NOTE:Only carry out the following steps when the valve clearance(s) require adjustment.
    Remove the camshafts.
    For additional information, refer to: Camshafts (303-01D Engine - 2.0L Duratec-ST (Zetec), In-vehicle Repair).
  1. NOTE:
    NOTE:Aim to set the valve clearance to the middle of the range.
    NOTE:
    NOTE:The number on the valve tappet indicates the valve tappet thickness.
    Determine the tappet thickness required.
    • Remove the valve tappet and read the thickness from the underside.
    • Calculate the valve tappet thickness required and insert the correct tappet.

        • 1. Inlet valves: tappet thickness required = thickness of currently installed tappets + measured valve clearance - 0.25 mm.

        2. Exhaust valves: tappet thickness required = thickness of currently installed tappets + measured valve clearance - 0.36 mm.
  1. CAUTION:
    CAUTION:Rotate the crankshaft until piston No. 1 is approximately 25 mm before TDC (BTDC).
    NOTE:
    NOTE:Do not install the timing belt at this stage.
    Install the camshafts.
    For additional information, refer to: Camshafts (303-01D Engine - 2.0L Duratec-ST (Zetec), In-vehicle Repair).
  1. NOTE:
    NOTE:Rotate the camshafts to measure the valve clearance.
    Recheck the valve clearance.
  1. Install the timing belt.
    For additional information, refer to: Timing Belt (303-01D Engine - 2.0L Duratec-ST (Zetec), In-vehicle Repair).

  1. NOTE:
    NOTE:Apply silicone grease to the inside of the spark plug connectors to a depth of 5-10 mm.
    Install the valve cover.
    1. Install the valve cover retaining bolts
    • Tighten the retaining bolts in two stages.
    • Stage 1: 2 Nm
    • Stage 2: 7 Nm
    1. Connect the PCV hose to the valve cover.
    1. Connect the spark plug electrical connectors.

  1. Connect the VCT valve electrical connector.

  1. NOTE:
    NOTE:Check that the gasket on the upper timing belt cover is seated correctly and adjust if necessary.
    Install the timing belt upper cover retaining bolts.
  1. Connect the battery ground cable.
    For additional information, refer to: Battery Disconnect (414-01 Battery, Mounting and Cables, General Procedures).
Vehicles with front and rear power windows
  1. Initialize the door window motors.
    For additional information, refer to: Door Window Motor Initialization (501-11 Glass, Frames and Mechanisms, General Procedures).

In-vehicle Repair > < Diagnosis and Testing|Engine