Cylinder head — disassembly and assembly (Power unit / Diesel engine 1.8 l / Ford Focus 1 1998-2004)

Special tool

	Valve Stem Cap Installer 303-037 (21-007A)
	Valve Spring Compressor 303-060 (21-024)
	Adapter for 303-060 (21-024) 303-060-05 (21-024-05)
	Camshaft seal installer 303-199A (21-110 A)
	Valve stem cotter installer 303-362 (21-156)
	Pliers for valve stem seals 303-390 (21-165)
	Socket wrench for cylinder head temperature sensor 303-680 (21-239)

Name	Specification
sealant	WSK-M2G348-A5
hypoid oil	SQM-2C-9022-AA
Engine oil	WSS-M2C912-A1

Disassembly

1. Remove the front engine lifting eye.

2. Remove the injectors and disconnect the glow plug wiring.

3. Remove glow plugs.

4. Remove the vacuum pump of system of brakes.

5. Using the special tool, remove the cylinder head temperature sensor (CHT) and oil pressure switch.

6. Remove the oil pressure switch.

7. Disconnect the elements located on the right side of a head of cylinders.

1.Motor lifting eye
2.Coolant fitting
coolant hose

8. Turn out the top bolts of fastening of a final collector. Turn out bolts of a flange of system recirculation of the fulfilled gases (EGR) (2 bolts).

9. Turn out the bottom bolts of fastening of a final collector.

10.

CAUTION: Loosen the nuts on the camshaft bearing caps, working evenly, loosening a turn at a time.

Remove the camshaft.

1. Remove the camshaft bearing caps Nos. 2 and 4.
2. Loosen the nuts on the other camshaft bearing caps, working evenly, loosening one turn at a time.
3. Remove the brake vacuum pump plunger.
Remove the bearing caps, bearing shells and oil-sealed camshaft.

11.

NOTE: Arrange the valve lifters in order to the side for later reuse.

Remove the valve lifters and valve shims.

12. Release the valve stem cotters. Place the socket on the valve spring seat and tap it gently with a hammer.

13.

NOTE: Install the cylinder head on wooden blocks.

Using the special tools, remove the valve springs.

1. Using the special tools, compress the valve springs.
2. Using the special tool, remove the valve cotters.
Remove the valves, valve cotters and valve springs and arrange them in order to the side.

14. Using the special tool, remove the valve stem seals.

Assembly

1. Grind the valves.

2.

CAUTION: Seal the grooves on the valve stems with protective sleeves.

NOTE: Remove protective sleeves only after valve stem seals have been installed.

Coat new valve stem seals with engine oil and install.

3. Coat the valves with hypoid oil and install them.

4. Install the valve spring.

Install the valve springs with the valve springs.
1. Using the special tool, compress the valve springs.
2.Install the cotters into the grooves on the valve stems.

NOTE: The writing on the shims is facing down.

NOTE: Coat the valve lifters and shims with engine oil before installing.

Install the valve lifters.

6. Install the lower camshaft bearing shells and apply engine oil to them.

7. Check the position of the camshaft. Install the camshaft and rotate it until the groove on the eccentric cam is parallel to the top edge of the cylinder head (larger semicircle facing up).