ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

ABOUT US
Cylinder Head > < Timing Belt

Focus RS 2003 (09.2002-)

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

Removal

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

  1. Disconnect the catalyst monitor sensor electrical connector.

  1. Detach the catalyst monitor sensor wiring harness from the retaining clip.

  1. Remove the catalytic converter retaining nuts.

  1. Remove the catalytic converter to lower support bracket retaining nuts.

  1. Loosen the catalytic converter upper bracket retaining bolt (catalytic converter shown removed for clarity).
  1. Lower the vehicle

  1. Remove the positive crankcase ventilation (PCV) heat shield retaining bolt.

  1. Remove the PCV valve heat shield.
    • Remove the PCV valve heat shield retaining clip.

  1. Remove the engine oil level indicator tube retaining bolt.

  1. Remove the exhaust manifold heat shield.

  1. CAUTION:
    CAUTION:The turbocharger must be protected from ingress of foreign material. Failure to follow this instruction may cause premature failure of the turbocharger.
    Disconnect the charge air cooler intake pipe from the turbocharger and position it to one side.
    • Using a suitable lint-free material cover the turbocharger outlet pipe to prevent ingress of foreign material.

  1. Disconnect the heated oxygen sensor (HO2S) sensor electrical connector.

  1. Disconnect the coolant supply hose from the turbocharger coolant supply pipe.

  1. Disconnect the wastegate control valve solenoid vacuum hose from the turbocharger.

  1. Disconnect the oil supply tube to the turbocharger.
    • Discard the sealing washers.

  1. Remove the catalytic converter upper bracket retaining bolts.

  1. NOTE:
    NOTE:Support the turbocharger and catalytic converter.
    Remove the turbocharger retaining bolts.
    • Discard the exhaust manifold to turbocharger gasket.

  1. Remove the exhaust manifold from the cylinder head.
    • Discard the exhaust manifold gasket.

Installation
  1. NOTE:
    NOTE:Install a new exhaust manifold gasket.
    Install the exhaust manifold from the cylinder head.

  1. NOTE:
    NOTE:Install a new exhaust manifold to turbocharger gasket.
    NOTE:
    NOTE:Do not tighten the turbocharger retaining bolts at this stage.
    Loosely install the turbocharger retaining bolts.
  1. Raise and support the vehicle.

  1. NOTE:
    NOTE:Do not tighten the catalytic converter retaining bolts at this stage.
    Loosely install the catalytic converter retaining bolts.

  1. NOTE:
    NOTE:Do not tighten the catalytic converter to lower support bracket retaining bolts at this stage.
    Loosely install the catalytic converter to lower bracket retaining bolts.
  1. Lower the vehicle.

  1. Tighten the turbocharger retaining bolts.

  1. Tighten the catalytic converter retaining bolts.

  1. Attach the catalyst monitor sensor wiring harness to the retaining clip.

  1. Connect the catalyst monitor sensor electrical connector.
  1. Lower the vehicle.

  1. Install the catalytic converter upper bracket retaining bolts.
  1. Raise the vehicle.

  1. Tighten the catalytic converter lower bracket retaining bolts.

  1. Tighten the catalytic converter upper bracket retaining bolt (catalytic converter shown removed for clarity).
  1. Lower the vehicle.

  1. NOTE:
    NOTE:Install new oil supply tube sealing washers.
    Connect the oil supply tube to the turbocharger.

  1. Connect the wastegate control valve solenoid vacuum hose to the turbocharger.

  1. Connect the coolant supply hose from the turbocharger coolant pipe.
  1. Remove the lint-free material from the turbocharger outlet pipe.

  1. CAUTION:
    CAUTION:Make sure that the inside of the charge air cooler intake pipe is clean and free from any oil residue, as this will reduce the installation grip of the pipe to the turbocharger. Failure to follow this instruction may result in damage to the turbocharger.
    Connect the charge air cooler intake pipe to the turbocharger.

  1. Install the exhaust manifold heat shield.

  1. Install the engine oil level indicator retaining bolt.

  1. Disconnect the heated oxygen sensor (HO2S) sensor electrical connector.

  1. Install the PCV heat shield retaining bolt.

  1. Install the PCV valve heat shield.

Cylinder Head > < Timing Belt