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In-vehicle Repair > < Diagnosis and Testing|Engine

Focus RS 2003 (09.2002-)

Engine - 2.0L Duratec-RS (Zetec) - Valve Clearance Focus RS 2003 (09/2002-)
General Procedures

Special Tool(s)

Compressor, Valve Adjustment

303-563 (21-218)
General Equipment
Feeler gauge
External micrometer
Sleeve (8 x 12 mm) or suitable washers
Materials
Name
Specification
Silicone grease for spark plug connector seals
A960-M1C171-AA 

Adjustment

  1. CAUTION:
    CAUTION:The valve clearances should be corrected by fitting different valve adjustment shims.
    Disconnect the battery ground cable. For additional information, refer to Section  414-01 Battery, Mounting and Cables.

  1. NOTE:
    NOTE:Do not remove the timing belt upper cover.
    Unscrew the timing belt upper cover bolts.

  1. Remove the exhaust heat shield.
    1. Remove the retaining nut.
    1. Remove the nuts and bolts.

  1. CAUTION:
    CAUTION:Do not pull on the cable when detaching the spark plug connector. If necessary, detach the connector from the ignition coil to prevent kinking of the cable. Turn the spark plug connector slightly before detaching it in order to loosen the seal.
    CAUTION:
    CAUTION:Detach the spark plug connector in line with the spark plug axis.
    NOTE:
    NOTE:Loosening sequence: From the outside inwards, working diagonally.
    Remove the valve cover.
    • Detach the spark plug connectors.
    1. Detach the crankcase ventilation hose.
    1. Remove the 10 bolts.

  1. CAUTION:
    CAUTION:Only turn the engine at the crankshaft and in the normal direction of rotation.
    Set the engine to ignition point for cylinder no. 1 (TDC).

  1. NOTE:
    NOTE:Make a note of the measured valve clearances, according to cylinder and valve.
    Measure valve clearance using a feeler gauge .
    • Permissible valve clearance: Intake (0.11 - 0.18 mm)
    • Permissible valve clearance: Exhaust (0.27 - 0.34 mm)
    • Turn the engine at the crankshaft in 180 degree steps in the direction of engine rotation and check the valve clearances of the remaining cylinders. The sequence of measurements is given by the firing order: 1-3-4-2.
  1. NOTE:
    NOTE:Only perform the following steps if the valves require adjusting.
    Install the special tool.

  1. NOTE:
    NOTE:Aim for a mid-range clearance (intake 0.15 mm; exhaust 0.30 mm).
    NOTE:
    NOTE:The number on the adjustment shim corresponds to the thickness of the shim. Example: 222 = 2.22 mm
    Determining the required shim thickness.
    • Remove the shims from the valve tappets and read off their thickness from the back of the shims (measure with an external micrometer if the thickness is no longer legible).
    • Determine the required shim thickness and insert.

        • 1. Intake valves: Required shim thickness = thickness of existing shim + measured valve clearance - 0.15 mm.

        2. Exhaust valves: Required shim thickness = thickness of existing shim + measured valve clearance - 0.30 mm.
  1. Change the shims.
  1. Remove the special tool.

  1. Recheck the valve clearance after fitting new shims.

  1. CAUTION:
    CAUTION:Use a blunt object (e.g. a plastic cable tie) to apply the silicone grease in order to avoid damaging the spark plug connector seal.
    CAUTION:
    CAUTION:Push on the spark plug connector in line with the spark plug axis.
    NOTE:
    NOTE:Coat the inside of the spark plug connectors with silicone grease to a depth of 5-10 mm.
    Install the valve cover.
    1. Screw in the ten bolts and tighten them in two stages.
    • 1, stage: 2 Nm.
    • 2, stage: 7 Nm.
    1. Install the crankcase ventilation hose.
    • Push on the spark plug connectors until they engage.

  1. NOTE:
    NOTE:Check the seating of the timing belt upper cover gasket and correct if necessary.
    Fit the timing belt upper cover.

  1. Install the heat shield.
    1. Install the retaining nut.
    1. Tighten the nuts and bolts.
  1. Connect the battery ground cable. For additional information, refer to Section  414-01 Battery, Mounting and Cables.
  1. Check fluid levels and correct if necessary.
  1. Check the routing of vacuum hoses and the wiring and secure them with cable ties .

In-vehicle Repair > < Diagnosis and Testing|Engine