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In-vehicle Repair|Oil Pan > < Exhaust Manifold

Focus RS 2003 (09.2002-)

Engine - 2.0L Duratec-RS (Zetec) - Cylinder Head Focus RS 2003 (09/2002-)
In-vehicle Repair

Special Tool(s)

Socket, Cylinder Head Bolt

303-392 (21-167)
General Equipment
Two locating studs M10 x 90 mm
Oil filter strap wrench
Materials
Name
Specification
Loctite 7070
A960-M1C171-AA 
Engine Oil
WSS-M2C912-A1 

Removal

WARNING:
WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may ignite. Failure to follow these instructions may result in personal injury.
  1. Release the fuel system pressure. For additional information, refer to Section  310-00A Fuel System - General Information.
  1. Remove the battery tray. For additional information, refer to Section  414-01 Battery, Mounting and Cables.
  1. Drain the cooling system. For additional information, refer to Section  303-03 Engine Cooling.
  1. Remove the camshafts.
    For additional information, refer to Camshafts in this section.

  1. Disconnect the brake booster vacuum pipe from the intake manifold.

  1. Disconnect the oil pressure switch electrical connector.
  1. Lower the vehicle.

  1. Remove the air intake tube.

  1. Disconnect the vacuum hose from the throttle body intake housing.

  1. Disconnect the intake air temperature (IAT) sensor electrical connector.

  1. Disconnect the vacuum hoses from the throttle body.

  1. Disconnect the fuel injection wiring harness electrical connector.

  1. Disconnect the cylinder head temperature (CHT) sensor electrical connector (generator shown removed for clarity).

  1. Disconnect the fuel supply and return line quick release couplings. For additional information, refer to Section  310-00A Fuel System - General Information.

  1. Disconnect the ground cable from the engine front lifting eye.

  1. Remove the exhaust manifold heat shield.

  1. Remove the exhaust manifold from the turbocharger.
    • Discard the gasket.

  1. Detach the thermostat housing from the cylinder head.
    • Discard the O-ring seal.

  1. Remove the oil level indicator and tube.

  1. Detach the power steering pump bracket from the engine.
    1. Remove the bolts.
    1. Remove the nuts.

  1. Detach the generator from the generator bracket.
    1. Loosen the bolt.
    1. Remove the bolt.

  1. Remove the generator bracket upper retaining bolt.

  1. CAUTION:
    CAUTION:The cylinder head must be cooled to ambient temperature.
    CAUTION:
    CAUTION:Remove the cylinder head bolts in the sequence shown.
    Remove the cylinder head bolts.
  1. NOTE:
    NOTE:Place the cylinder head on a clean surface.
    Remove the cylinder head.

Installation

  1. Check the cylinder head for distortion. For additional information, refer to Section  303-00 Engine System - General Information.
  1. Clean the mating faces of the cylinder head and cylinder block with Loctite 7070.

  1. Fabricate two locating studs as shown.

  1. CAUTION:
    CAUTION:The choice of cylinder head gasket depends on the cast cylinder block number.
    Prepare the cylinder block for the cylinder head installation.
    1. Check the cylinder block number.
    1. Position a new cylinder head gasket on the cylinder block.
    1. Install the fabricated locating studs.
    1. Check that the guide bushes are correctly seated.

  1. CAUTION:
    CAUTION:The cylinder head bolts must only be used twice. Mark the cylinder head bolts using a center punch to indicate usage.
    CAUTION:
    CAUTION:Install new cylinder head bolts as necessary.
    Install the cylinder head.
    • Using the special tool, tighten the cylinder head bolts in the sequence shown in three stages.
    • Stage 1: 20 Nm
    • Stage 2: 40 Nm
    • Stage 3: 90 degrees.
  1. Install the camshafts.
    For additional information, refer to Camshafts in this section.

  1. Attach the power steering pump bracket to the engine.

  1. Install the oil level indicator and tube.

  1. Install the generator bracket upper retaining bolt.

  1. Attach the generator to the generator bracket.

  1. NOTE:
    NOTE:Install a new thermostat housing O-ring seal.
    Attach the thermostat housing to the cylinder head.

  1. NOTE:
    NOTE:Install a new exhaust manifold gasket.
    Attach the exhaust manifold to the turbocharger.

  1. Install the exhaust manifold heat shield.

  1. Connect the ground cable to the engine front lifting eye.

  1. Connect the fuel supply and return line quick release couplings. For additional information, refer to Section  310-00A Fuel System - General Information.

  1. Connect the cylinder head temperature (CHT) sensor electrical connector (generator shown removed for clarity).

  1. Connect the fuel injection wiring harness electrical connector.

  1. Connect the vacuum hoses to the throttle body.

  1. Connect the intake air temperature (IAT) sensor electrical connector.

  1. Connect the vaccum hose to the throttle body intake housing.

  1. Install the air intake tube.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Connect the oil pressure switch electrical connector.

  1. Connect the brake booster vacuum pipe to the intake manifold.
  1. Drain the engine oil.

  1. Using a suitable oil filter strap wrench, remove the oil filter (engine shown removed for clarity).
    • Discard the filter.
  1. NOTE:
    NOTE:Install a new oil filter.
    Install the oil filter.
  1. Lower the vehicle.
  1. Install the battery tray. For additional information, refer to Section  414-01 Battery, Mounting and Cables.
  1. Fill and bleed the cooling system. For additional information, refer to Section  303-03 Engine Cooling.
  1. Fill the engine with engine oil

In-vehicle Repair|Oil Pan > < Exhaust Manifold