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In-vehicle Repair|Oil Pan > < Timing Belt - Vehicles Built From: 04-2005

Focus 2004.75 (07.2004-)

Engine - 1.6L Duratec-16V Ti-VCT (Sigma) - Cylinder Head Focus 2004.75 (07/2004-)
In-vehicle Repair

Special Tool(s)

Socket, Cylinder Head Bolt

303-392

Remover/Installer, Cooling Hose Clamp

303-397
Materials
Name
Specification
Grease
SA-M1C9107-A 
  1. CAUTION:
    CAUTION:Do not smoke or use any kind of naked flame when working on or near any fuel-related components. Highly flammable vapors are always present and may ignite. Failure to observe this instruction can lead to injury.
  1. Release fuel system pressure.
    For additional information, refer to: Fuel System - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma)/1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (310-00 Fuel System - General Information, Diagnosis and Testing).
  1. Remove the battery tray.
    For additional information, refer to: Battery Tray - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma)/1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (414-01 Battery, Mounting and Cables, Removal and Installation).
  1. Drain the coolant.
    For additional information, refer to: Cooling System Draining, Filling and Bleeding (303-03B Engine Cooling - 1.6L Duratec-16V Ti-VCT (Sigma), General Procedures).

  1. Connect the heated oxygen sensor (HO2S) and the left-hand catalyst monitor sensor connectors.
    • Detach the connector bracket from the cylinder head.

  1. Connect the heated oxygen sensor (HO2S) and the right-hand catalyst monitor sensor connectors.

7. Remove the components in the order indicated in the following illustration(s) and table(s).

 
Item
Part Number
Description
1
-
Exhaust heat shield bolts
2
-
Exhaust heat shield
3
-
Exhaust manifold bolt and nuts
See Installation Detail
4
-
Flexible exhaust pipe nuts.
See Removal Detail
See Installation Detail
5
-
Exhaust pipe rubber insulators
6
-
Catalytic converter bracket bolts
See Removal Detail

 
Item
Part Number
Description
7
-
Oil dipstick tube bracket bolt
8
-
Oil dipstick tube
9
-
Vacuum line, brake servo
10
-
Vacuum line
11
-
Crankcase breather hose
12
-
Cable ties

 
Item
Part Number
Description
13
-
Coolant distribution connection
See Removal Detail
See Installation Detail
14
-
Intake manifold
See Removal Detail
See Installation Detail
15
-
Cylinder head
See Removal Detail
See Installation Detail

8. To install, reverse the removal procedure.

  1. NOTE:
    NOTE:Install a new oil filter.
    Change the engine oil.
    For additional information, refer to: Specifications (303-01B Engine - 1.6L Duratec-16V Ti-VCT (Sigma), Specifications).

Removal Details

Item 4 : Flexible exhaust pipe nuts.
  1. WARNING:
    WARNING:Excessive bending of the flexible exhaust pipe can cause damage that may lead to component failure.
    Protect flexible exhaust pipes with a suitable support sleeve or reinforcement.

Item 6 : Catalytic converter bracket bolts

NOTE:
NOTE:The catalytic converter remains in the vehicle.

Item 13 : Coolant distribution connection

  1. Remove the camshafts.
    For additional information, refer to: Camshafts (303-01B Engine - 1.6L Duratec-16V Ti-VCT (Sigma), In-vehicle Repair).

  1. Using the special tool, remove the coolant hose from the coolant outlet connection.

  1. Detach the coolant distribution connection from the cylinder head.
    • Discard the gasket.

  1. Remove the rear timing belt cover.

Item 14 : Intake manifold
  1. Detach the fuel supply line bracket from the intake manifold.

  1. Detach the fuel supply line from the fuel rail.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

  1. Remove the lower bolts from the intake manifold.

  1. Detach the engine wiring harness connector.

Item 15 : Cylinder head
  1. WARNING:
    WARNING:Only remove the cylinder head bolts once the cylinder head temperature has dropped below 30 degrees C.
    Remove the cylinder head bolts in the sequence indicated using the special tool.

Installation Details

Item 15 : Cylinder head
  1. WARNING:
    WARNING:The new cylinder head gasket must be of the same thickness as the original gasket (holes or teeth).
    NOTE:
    NOTE:Install a new cylinder head gasket.
    NOTE:
    NOTE:Position the cylinder head on the two guide sleeves.
    Using the special tool, install the cylinder head.
    • Tighten the bolts in the sequence shown, in three stages.
    • Stage 1: 15 Nm
    • Stage 2: 30 Nm
    • Stage 3: 90 degrees

Item 14 : Intake manifold
  1. Install the lower bolts of the intake manifold.

  1. Connect the engine wiring harness connector.

  1. Attach the fuel supply line to the fuel rail.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

  1. Attach the fuel supply line bracket to the intake manifold.

Item 13 : Coolant distribution connection
  1. NOTE:
    NOTE:Install a new coolant distribution connection gasket.
    Attach the coolant distribution connection to the cylinder head.

  1. Using the special tool, connect the coolant hose to the coolant outlet connection.

  1. Install the rear timing belt cover.
  1. Install the camshafts.
    For additional information, refer to: Camshafts (303-01B Engine - 1.6L Duratec-16V Ti-VCT (Sigma), In-vehicle Repair).

Item 4 : Flexible exhaust pipe nuts.

  1. NOTE:
    NOTE:Install a new flange gasket.
    Coat the flexible exhaust pipe nuts with grease and install.

  1. Remove the support sleeves.

Item 3 : Exhaust manifold bolt and nuts

  1. NOTE:
    NOTE:Install a new exhaust manifold gasket.
    Coat the bolt and nuts with grease and install.

In-vehicle Repair|Oil Pan > < Timing Belt - Vehicles Built From: 04-2005