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
   
   

   

   

   Fig. Cylinder head bolt loosening sequence-2.0L (VIN 3) engine

To install:

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
   
   

   

   

   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.
    
    
    

    

    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.
    
    
    

    

    Fig. Locating stud-2.0L (VIN 5) engine
    
    
    
    

    

    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
   
   

   

   

   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
   
   

   

   

   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.
   
   
   

   

   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
   
   

   

   

   Fig. Cylinder head loosening sequence-2.0L (VIN P) engine

To install:

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.
   
   
   

   

   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.
   
   
   

   

   Fig. Apply silicone gasket sealant where indicated-2.3L (VIN Z) and 2.0L (VIN N) engines
   
   
   
   

   

   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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