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Engine - Vehicles Built Up To: 04-2005 > < Cylinder Head

Focus 2004.75 (07.2004-)

Engine - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) - Engine—Vehicles Built From: 04/2005 Focus 2004.75 (07/2004-)

Assembly

Special Tool(s)
205-072
Universal Flange Holding Wrench

303-1054
Locking Tool, Timing Belt Tensioner

303-122
Lifting Bracket, Engine

303-376B
Alignment Plate, Camshaft

303-392
Socket, Cylinder Head Bolt

303-393
Locking Tool, Flywheel

303-395
Installer, Crankshaft Seal

303-435
Mounting Stand

303-435-06
Mounting Bracket for 303-435

303-435-14A
Mounting Plate for 303-435-06

303-748
Locking Tool, Crankshaft
Materials
Name
Specification
Engine Oil - 5W-30
WSS-M2C912-A1
Sealant - Loctite 518
WSK-M2G348-A5
Silicone Sealant
WSE-M4G323-A4
  1. Special Tool(s): 303-435, 303-435-06, 303-435-14A

  1. Torque: 9 Nm

  1. Torque: 9 Nm

  1. Torque: 9 Nm

  1. Install 5x M8x20 studs.

  1. NOTE:
    NOTE:The component must be installed within 5 minutes of applying the sealant.
    Material: Silicone Sealant

  1. Torque:
    Stage 1:
    10 Nm
    Stage 2:
    20 Nm

  1. Special Tool(s): 303-395
    Material: Engine Oil - 5W-30

  1.  
    1. Torque: 9 Nm
    1. Torque: 20 Nm
    1. Torque: 9 Nm

  1. CAUTION:
    CAUTION:Make sure that no fluids are present in the cylinder head bolt threaded bores.
    CAUTION:
    CAUTION:Make sure that new bolts are installed.
    Install a new cylinder head gasket.
    Special Tool(s): 303-392
    Torque:
    Stage 1:
    15 Nm
    Stage 2:
    30 Nm
    Stage 3:
    90°

  1. Torque: 9 Nm

  1. NOTE:
    NOTE:Make sure that these components are installed to the noted removal position.

  1. NOTE:
    NOTE:Make sure that these components are installed to the noted removal position.
    Position the camshafts in place so that none of the cams are at full lift.
    Material: Engine Oil - 5W-30
    Material: Sealant - Loctite 518
    Torque:
    Stage 1:
    7 Nm
    Stage 2:
    45°
  1. NOTE:
    NOTE:This step is only required when installing a new component.
    Refer to: Valve Clearance Adjustment (303-01A Engine - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), General Procedures).

  1. NOTE:
    NOTE:Make sure that a new component is installed.
    Special Tool(s): 303-395
    Material: Engine Oil - 5W-30

  1. Torque: 9 Nm

  1. CAUTION:
    CAUTION:Make sure that new bolts are installed.
    NOTE:
    NOTE:Only tighten the bolts finger tight at this stage.
    NOTE:
    NOTE:Make sure that the camshaft pulleys can rotate on the camshafts.

  1. Special Tool(s): 303-376B

  1. WARNING:
    WARNING:Take extra care when handling the compressed spring.
    1. Install the timing belt, beginning with the crankshaft timing pulley and working anti-clockwise.
    1. Torque: 25 Nm

  1. WARNING:
    WARNING:Take extra care when handling the compressed spring.
    Remove the special tool.
    Special Tool(s): 303-1054

  1. Torque: 9 Nm

  1. CAUTION:
    CAUTION:Make sure that a new bolt is installed.
    • a = 42 mm = bolt M12 x 29
    • a = 52 mm = bolt M12 x 44.5
    • Torque:
      Stage 1:
      45 Nm
      Stage 2:
      90°

  1. Special Tool(s): 303-748

  1. CAUTION:
    CAUTION:Only rotate the crankshaft clockwise.
    Turn the crankshaft until it stops against the special tool.

  1. Special Tool(s): 205-072
    Torque: 60 Nm

  1. Remove the special tool.
    Special Tool(s): 303-376B

  1. Remove the special tool.
    Special Tool(s): 303-748

  1. CAUTION:
    CAUTION:Only rotate the crankshaft clockwise.
    Turn the crankshaft approximately one and three quarters of a turn.

  1. Attach the special tool.
    Special Tool(s): 303-748

  1. CAUTION:
    CAUTION:Only rotate the crankshaft clockwise.
    Turn the crankshaft until it stops against the special tool.

  1. NOTE:
    NOTE:The special tool can only be installed if the valve timing is correct.
    Attach the special tool.
    Special Tool(s): 303-376B
  1. Remove the special tool.
    Special Tool(s): 303-376B

  1. Remove the special tool.
    Special Tool(s): 303-748

  1. Torque: 20 Nm

  1. Torque: 15 Nm

  1. NOTE:
    NOTE:The gasket is to be reused unless damaged.
    1. Screw in bolt 1 by 3 - 4 turns.
    1. Bolts 2 - 13
      Torque: 9 Nm

  1.  
    1. Torque: 4 Nm
    1. Torque: 18 Nm

  1. Torque: 9 Nm

  1.  
    1. NOTE:
      NOTE:Only tighten the bolt finger tight at this stage.
    1. Torque: 55 Nm
    1. Torque: 55 Nm
    1. Torque: 10 Nm

  1.  
    1. Torque: 9 Nm
    1. NOTE:
      NOTE:Only tighten the bolts finger tight at this stage.

  1. Install the following items:
    1. Torque: 25 Nm
    1. Torque: 47 Nm

  1. NOTE:
    NOTE:Make sure that a new component is installed.
    Torque: 25 Nm

  1. Special Tool(s): 303-393
    Torque:
    Stage 1:
    30 Nm
    Stage 2:
    80°

  1. Remove the special tool.
    Special Tool(s): 303-393

  1. Install the following items:
    1. Torque: 15 Nm
    1. Torque: 15 Nm
    1. Torque: 8 Nm

  1. NOTE:
    NOTE:The seals are to be reused unless damaged.
    Torque: 27 Nm

  1. Install the special tool.
    Special Tool(s): 303-122

  1. Remove the special tool.
    Special Tool(s): 303-435, 303-435-06, 303-435-14A

Engine - Vehicles Built Up To: 04-2005 > < Cylinder Head