Sunday, October 30, 2011

How to remove Cylinder head on 2003 Ford Focus?


Cylinder Head


Removal & Installation



2.0L (VIN 3) Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Disconnect the negative battery cable.
  3. Drain the cooling system.
  4. Relieve the fuel system pressure.
  5. Remove or disconnect the following:

    Air cleaner assembly outlet tube
    Timing belt
  6. Tag and disconnect the vacuum hoses from the following components:

    Positive Crankcase Ventilation (PCV) valve
    Throttle body
    Fuel pressure sensor
    Intake manifold
  7. Remove or disconnect the following:

    Speed control and accelerator cables from the control lever
    Fuel charging electrical connectors at the main engine connector
    Crankshaft Position (CKP) sensor and Heated Oxygen (HO 2 S) sensor electrical connections
    Fuel line
    Power steering pump and bracket
    Alternator
    Engine oil dipstick tube
    Splash shield
    Air conditioning compressor
    Spark plug wires
    Valve cover
    Upper radiator hose
    Heater hose
    Camshafts
    Ignition coil
    Thermostat housing
    Cylinder head bolts. Mark each bolt with a punch and loosen them in the sequence shown.
    Cylinder head and the gasket

    Click image to see an enlarged view
    Fig. Cylinder head bolt loosening sequence-2.0L (VIN 3) engine
To install:
Click image to see an enlarged view
Fig. Cylinder head torque sequence-2.0L (VIN 3) engine

NOTE
The cylinder head bolts may be reused twice. Replace bolts that have two punch marks.

  1. Lubricate the cylinder bolts when engine oil.
  2. Install the cylinder head and tighten the bolts in sequence as follows:
    1. Step 1: 15 ft. lbs. (20 Nm)
    2. Step 2: 30 ft. lbs. (40 Nm)
    3. Step 3: Plus 90 degrees
  3. Install or connect the following:

    Thermostat housing
    Ignition coil and the camshafts
    Heater and upper radiator hoses
    Valve cover

    Click image to see an enlarged view
    Fig. Valve cover torque sequence-2.0L (VIN 3) Engine
    Spark plugs
    Spark plug wires
    Air conditioning compressor
    Splash shield
    Engine oil dipstick tube
    Alternator and the power steering reservoir and bracket
    Fuel line
    CKP sensor, HO 2 sensor and 2 main fuel charging electrical connections
    Accelerator cable and if equipped, the speed control cable to the control lever
  4. Connect the vacuum hoses to the following components:

    PCV valve
    Throttle body
    Fuel pressure sensor
    Intake manifold
  5. Install or connect the following:

    Timing belt
    Air cleaner outlet tube
    Negative battery cable
  6. Fill the cooling system.
  7. Start the engine and check for leaks.
2.0L (VIN 5) Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Release the fuel system pressure.
  3. Disconnect the battery.
  4. Release the coolant system pressure.
  5. Raise and support the vehicle.
  6. Drain the coolant from the radiator. Allow the coolant to drain into a suitable container. Install the radiator drain plug after draining the coolant.
  7. Disconnect the brake booster pipe from the intake manifold.
  8. Disconnect the oil pressure switch electrical connector.
  9. Remove the intake manifold lower retaining bolt.
  10. Disconnect the knock sensor electrical connector and separate it from the intake manifold.
  11. Disconnect the catalyst monitor sensor electrical connector and separate it from the bracket.
  12. Lower the vehicle.
  13. Remove the air cleaner.
  14. Remove the splash shield.
  15. Disconnect the accelerator cable from the throttle body.
  16. Disconnect the intake manifold runner control (IMRC) actuator cable from the IMRC lever.
  17. Disconnect the vacuum hoses from the intake manifold.
  18. Disconnect the fuel injector wiring harness.
  19. Disconnect the camshaft position (CMP) sensor electrical connector.
  20. Disconnect the fuel lines.
  21. Disconnect the ground cable from the engine lifting eye.
  22. Remove the exhaust manifold.
  23. Disconnect the thermostat housing.
  24. Disconnect the power steering pipe bracket from the cylinder head.
  25. Disconnect the power steering pump bracket from the cylinder head and cylinder block.
  26. Disconnect the generator.
  27. Disconnect the wiring harness from the electronic ignition (EI) coil and from the engine coolant temperature (ECT) sensor.
  28. Remove the upper bolt from the generator bracket.
  29. Remove the camshafts.
    NOTE
    Keep the valve tappets in order for installation.
  30. Remove the valve tappets.
    CAUTION
    Cylinder head bolts can only be used twice, mark the bolts to indicate usage.


    CAUTION
    The cylinder head must be cooled to ambient temperature.
  31. Remove the cylinder head bolts in the sequence shown.
  32. Remove the cylinder head.

    Click image to see an enlarged view
    Fig. Cylinder head bolt removal sequence-2.0L (VIN 5) engine
  33. Using a spatula, remove gasket residue.
  34. Thoroughly clean the threaded holes of the cylinder head bolts.
  35. Check the cylinder head distortion.
  36. Make up two locating studs as shown.

    Click image to see an enlarged view
    Fig. Locating stud-2.0L (VIN 5) engine


    Click image to see an enlarged view
    Fig. Cylinder head bolt torque sequence-2.0L (VIN 5) engine
  37. Install a new cylinder head gasket.
  38. Insert the fabricated locating studs. Check that the locating studs are seated correctly.
  39. Install the cylinder head.
  40. Tighten the cylinder head bolts in sequence as follows:
    1. Step 1: 15 ft. lbs. (20 Nm)
    2. Step 2: 30 ft. lbs. (40 Nm)
    3. Step 3: Plus 90 degrees.
      NOTE
      Coat the valve tappets with clean engine oil before installation.
  41. Install the valve tappets in order.
  42. Install the camshafts.
  43. Check the valve clearance and, if necessary, adjust.
  44. Attach the power steering pump bracket to the cylinder head and cylinder block.
  45. Install the generator bracket bolt.
  46. Connect the wiring harness to the electric ignition (EI) coil and to the engine coolant temperature (ECT) sensor.
  47. Attach the generator.
  48. Attach the power steering pipe bracket to the cylinder head.
  49. Install the intake manifold lower retaining bolt.
  50. Connect the catalyst monitor sensor electrical connector and attach it to the bracket.
  51. Connect the knock sensor electrical connector.
  52. Install the exhaust manifold.
    NOTE
    Install a new thermostat housing gasket.
  53. Attach the thermostat housing. Tighten the bolts to 15 ft. lbs. (20 Nm).
  54. Attach the fuel lines.
  55. Attach the ground cable to the engine lifting bracket.
  56. Connect the camshaft position (CMP) sensor connector.
  57. Connect the fuel injector wiring harness.
  58. Attach the accelerator cable and the speed control cable (if equipped) to the throttle body.
  59. Install the splash shield.
  60. Attach the intake manifold runner control (IMRC) actuator cable to the IMRC lever.
  61. Attach the vacuum hoses to the intake manifold.
  62. Install the air cleaner.
  63. Raise and support the vehicle.
  64. Connect the oil pressure switch electrical connector.
  65. Attach the brake booster pipe to the intake manifold.
  66. Drain and fill the engine with clean engine oil.
  67. Connect the battery ground cable.
  68. Fill and bleed the cooling system.
2.0L (VIN N) Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Drain the cooling system.
  3. Relieve the fuel system pressure.
  4. Remove or disconnect the following:

    Negative battery cable
    Battery tray
    Cooling fans
    Catalytic converter from the muffler assembly
    Catalytic converter support bracket
    Engine heat shield, if equipped

    Click image to see an enlarged view
    Fig. Removing the engine heat shield from 2.0L (VIN N) engines
    Exhaust sensor electrical connectors
    Catalytic converter and secure it aside with mechanic-s wire or equivalent
    Alternator
    Fuel rail
    Intake manifold; see -Intake Manifold- in this section
    Timing drive components; see -Timing Chain and Sprockets-
  5. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.
  6. Remove the camshafts from the engine by following this procedure:
    1. Loosen the camshaft bearing cap bolts, in sequence, one turn at a time.
    2. Repeat the first step until all tension is released from the camshaft bearing caps.
    3. Remove the camshaft bearing caps.
    4. Remove the camshaft and valve lifters (tappets). See -Camshaft and Valve Lifters- in this section.
  7. Remove or disconnect the following:

    Secondary air injection (AIR) vacuum regulator electrical connector and hose, if equipped
    Hoses from the AIR valve, if equipped
    Upper exhaust sensor electrical connectors, if equipped
    Exhaust gas recirculation (EGR) valve electrical connector
    Coolant bypass
    EGR coolant hose
    Cylinder head bolts
    Cylinder head

    Click image to see an enlarged view
    Fig. Camshaft bolt removal sequence-2.0L (VIN N) engine
To install:
  1. Inspect the cylinder head mating surfaces.
  2. Apply silicone gasket sealant to the locations shown.

    Click image to see an enlarged view
    Fig. Applying silicone gasket sealant for cylinder head installation
  3. Install a new cylinder head gasket and cylinder head.
  4. Using new bolts, tighten the cylinder bolts as follows:
    1. Step 1: 44 inch lbs. (5 Nm)
    2. Step 2: 11 ft. lbs. (15 Nm)
    3. Step 3: 33 ft. lbs. (45 Nm)
    4. Step 4: Plus 90 degrees
    5. Step 5: Plus 90 degrees again
  5. Install or connect the following:

    EGR coolant hose
    Coolant bypass, using new gasket. Tighten to 89 inch lbs. (10 Nm).
    EGR valve electrical connector
    Catalytic converter, using new gasket and nuts. Tighten nuts to 41 ft. lbs. (55 Nm).
    Exhaust sensor electrical connectors
    Upper exhaust sensor electrical connectors, if equipped
    Hoses to the AIR valve, if equipped
    Secondary air injection (AIR) vacuum regulator electrical connector and hose, if equipped
    Engine heat shield, if equipped
    Catalytic converter support bracket and tighten bolts to 35 ft. lbs. (47 Nm)
    Catalytic converter to muffler assembly, using new gasket and nuts
    Valve lifters and camshafts
    Intake manifold
    Fuel rail
    Alternator
    Cooling fan
    Battery tray
    Negative battery cable
  6. Drain the engine oil.
  7. Change the oil filter and fill the engine with oil.
  8. Fill and bleed the cooling system to the correct level.
  9. Start the engine and check for leaks.
2.0L (VIN P) Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Disconnect the negative battery cable.
  3. Drain the cooling system.
  4. Relieve the fuel system pressure.
  5. Remove or disconnect the following:

    Timing belt
    Engine air cleaner intake tube
  6. Tag and disconnect the vacuum hoses from the following components:

    Exhaust Gas Recirculation (EGR) valve
    Positive Crankcase Ventilation (PCV) valve
    Throttle body
    Fuel pressure regulator
    Intake manifold
  7. Remove or disconnect the following:

    Accelerator cable, throttle control lever and if equipped, the speed control cable
    Speed control cable bracket bolt, if equipped
    2 fuel charging wiring electrical connections
    Crankshaft Position (CKP) sensor and Heated Oxygen (HO 2 S) sensor electrical connections
    Fuel supply line
    Power steering pressure hose bracket bolts, then position the bracket and hose aside
    Alternator lower bolt, loosen only
    Alternator upper bolt and pivot the alternator forward
    Engine oil dipstick tube bracket bolt
    Exhaust Gas Recirculation (EGR) tube
    Exhaust manifold heat shield
    Catalytic converter
    Right-hand splash shield bolts and the shield
    Engine oil dipstick tube from the cylinder block
    Air conditioning compressor
    Engine accessory drive bracket
    Valve cover
    Upper radiator hose
    Heater hose
    Cylinder head bolts. Loosen the bolts in sequence.
    Cylinder head and gasket

    Click image to see an enlarged view
    Fig. Cylinder head loosening sequence-2.0L (VIN P) engine
To install:
Click image to see an enlarged view
Fig. Cylinder head torque sequence-2.0L (VIN P) engine

NOTE
Use new cylinder head bolts for assembly.

  1. Install the cylinder head and tighten the bolts in sequence as follows:
    1. Step 1: 37 ft. lbs. (50 Nm)
    2. Step 2: Loosen all bolts 1 / 2 turn
    3. Step 3: 37 ft. lbs. (50 Nm)
    4. Step 4: Plus 90 degrees
    5. Step 6: Plus 90 degrees
  2. Install or connect the following:

    Accessory drive bracket. Tighten the fasteners to 30-40 ft. lbs. (40-55 Nm)
    Air conditioning line bracket and tighten the bolt to 15-18 ft. lbs. (20-25 Nm)
    Valve cover
    Air conditioning compressor
    Right-hand splash shield
    Engine oil dipstick tube
    Heater and upper radiator hoses
    Timing belt and alternator
    Power steering pressure hose
    CKP sensor and 2 main fuel charging electrical connections
    Engine oil dipstick tube bolt
    EGR valve tube
    Fuel supply line
    Catalytic converter
    Heat shield
    Speed control cable bracket, if equipped
    Throttle control lever, accelerator cable and if equipped, the speed control cable
  3. Connect the vacuum hoses to the following components:

    EGR valve
    PCV valve
    Throttle body
    Fuel pressure regulator
    Intake manifold
    Air cleaner outlet tube
    Negative battery cable
  4. Fill the cooling system.
  5. Start the engine and check for leaks.

    Click image to see an enlarged view
    Fig. Exploded view of the cylinder head, exhaust manifold and intake manifold mounting-2.0L (VIN P) engine
2.3L (VIN Z) Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Disconnect the battery ground cable.
  3. Drain the cooling system.
    CAUTION
    During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, which enters the oil passages, coolant passages or the oil pan can cause engine failure.


    CAUTION
    The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley. Therefore the engine must be retimed each time the damper is removed. Otherwise severe damage can occur.
  4. Remove the camshafts.
  5. Remove the catalytic converter.
  6. Remove the fuel injection supply manifold.
  7. Remove the intake manifold.
  8. Remove the fuel injection supply manifold spacers.
  9. Disconnect the exhaust gas recirculation (EGR) vacuum regulator electrical connector.
  10. Remove the hoses from the air control valve.
  11. Disconnect the EGR valve electrical connector.
  12. Remove the coolant hoses from the coolant bypass.
  13. Remove the coolant bypass bolts and the coolant bypass.
  14. Disconnect the EGR coolant hose.
  15. Disconnect the radio interference capacitor.
  16. Remove the bolts and the cylinder head. Discard the bolts.
  17. Remove and discard the head gasket.
To install:
  1. Inspect the cylinder head mating surfaces.
    CAUTION
    Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths.
  2. Clean the cylinder head gasket surfaces with metal surface cleaner.
  3. Apply silicone gasket and sealant to the locations shown.

    Click image to see an enlarged view
    Fig. Apply silicone gasket sealant where indicated-2.3L (VIN Z) and 2.0L (VIN N) engines


    Click image to see an enlarged view
    Fig. Cylinder head bolt torque sequence-2.3L (VIN Z) and 2.0L (VIN N) engines
  4. Install a new head gasket.
    NOTE
    The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.


    NOTE
    Lubricate the cylinder head bolts with clean engine oil.
  5. Install the cylinder head and new bolts. Tighten the bolts in sequence as follows.
    1. Step 1: 44 inch lbs. (5 Nm)
    2. Step 2: 11 ft. lbs. (15 Nm)
    3. Step 3: 33 ft. lbs. (45 Nm)
    4. Step 4: Plus 90 degrees
    5. Step 5: Plus 90 degrees
  6. Connect the radio interference capacitor electrical connector.
  7. Install the EGR coolant hose.
  8. Install the coolant bypass and tighten the bolts to 89 inch lbs. (10 Nm).
  9. Install the coolant hoses onto the coolant bypass.
  10. Connect the EGR valve electrical connector.
  11. Install the air control valve hoses.
  12. Connect the EGR vacuum regulator electrical connector.
  13. Install the fuel injector supply manifold spacers.
  14. Install the intake manifold.
  15. Install the fuel injector supply manifold.
  16. Install the catalytic converter.
  17. Install the camshafts.
  18. Connect the battery ground cable.
  19. Fill and bleed the cooling system.
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Drain the cooling system.
  3. Relieve the fuel system pressure.
  4. Remove or disconnect the following:

    Negative battery cable
    Battery tray
    Cooling fan
    Catalytic converter from the muffler assembly
    Catalytic converter support bracket
    Engine heat shield
    Exhaust sensor electrical connectors
    Catalytic converter and secure it aside with mechanic-s wire or equivalent
    Alternator
    Fuel rail
    Intake manifold
    Valve lifters
    Exhaust gas recirculation (EGR) valve electrical connector
    Coolant bypass
    EGR coolant hose
    Cylinder head bolts
    Cylinder head
To install:
  1. Inspect the cylinder head mating surfaces.
  2. Apply silicone gasket sealant to the locations shown.
  3. Install a new cylinder head gasket and cylinder head.
  4. Using new bolts, tighten the cylinder bolts as follows:
    1. Step 1: 44 inch lbs. (5 Nm)
    2. Step 2: 11 ft. lbs. (15 Nm)
    3. Step 3: 33 ft. lbs. (45 Nm)
    4. Step 4: Plus 90 degrees
    5. Step 5: Plus 90 degrees again
  5. Install or connect the following:

    EGR coolant hose
    Coolant bypass, using new gasket. Tighten to 89 inch lbs. (10 Nm).
    EGR valve electrical connector
    Catalytic converter, using new gasket and nuts. Tighten nuts to 41 ft. lbs. (55 Nm).
    Exhaust sensor electrical connectors
    Engine heat shield
    Catalytic converter support bracket and tighten bolts to 35 ft. lbs. (47 Nm)
    Catalytic converter to muffler assembly, using new gasket and nuts
    Valve lifters
    Intake manifold
    Fuel rail
    Alternator
    Cooling fan
    Battery tray
    Negative battery cable
  6. Drain the engine oil.
  7. Change the oil filter and fill the engine with oil.
  8. Fill the cooling system to the correct level.
  9. Start the engine and check for leaks.



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