Cylinder head — disassembly and assembly (Focus 1)

Special tool

	Valve stem oil seal installation tool 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 cracker installation tool 303-362 (21-156)
	Valve stem seal pliers 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
Motor oil	WSS-M2C912-A1

Disassembly

1. Remove the front engine lifting eye.

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

3. Remove the glow plugs.

4. Remove the brake system vacuum pump.

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

6. Remove the oil pressure switch.

7. Disconnect the components located on the right side of the cylinder head.

1. Engine lifting eye
2.Coolant fitting
Coolant hose

8. Remove the upper exhaust manifold mounting bolts. Remove the exhaust gas recirculation (EGR) flange bolts (2 bolts).

9. Remove the lower exhaust manifold mounting bolts.

10.

CAUTION: Loosen the camshaft bearing cap nuts by working evenly, one turn at a time.

Remove the camshaft.

1. Remove 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 plunger of the brake system vacuum pump.
Remove the bearing caps, bearing shells and camshaft with oil seal.

Remove the bearing caps, bearing shells and camshaft with oil seal.

11.

NOTE: Place the valve lifters in order and set them aside for future reuse.

Remove the valve lifters and valve adjusting shims.

12. Release the valve stem crackers. Place the socket head on the valve spring retainer and tap it gently with a hammer.

12. Release the valve stem crackers. Place the socket head on the valve spring retainer and tap it…

13.

NOTE: Place the cylinder head on wooden blocks.

Using special tools, remove the valve springs.

1. Using special tools, compress the valve springs.
2. Using a special tool, remove the valve crackers.
Remove the valves, valve keepers and valve springs and place them in order to the side.

Remove the valves, valve keepers and valve springs and place them in order to the side.

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

Assembly

1. Grind the valves.

2.

CAUTION: Cover the valve stem grooves with protective sleeves.

NOTE: Remove the protective bushings only after installing the valve stem seals.

Apply engine oil to new valve stem seals and install them.

3. Apply hypoid oil to the valves and install them.

4. Install the valve spring.

Install the valve springs with valve spring retainers.
1. Using a special tool, compress the valve springs.
2. Install crackers into the grooves on the valve stems.

2. Install crackers into the grooves on the valve stems.

NOTE: The writing on the adjusting shims faces down.

NOTE: Apply engine oil to the valve lifters and shims before installation.

Install the valve lifters.

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

7. Align the camshaft. Install the camshaft and turn it until the groove on the eccentric cam is parallel to the top edge of the cylinder head (the larger semicircle faces up).

7. Align the camshaft. Install the camshaft and turn it until the groove on the eccentric cam is…

8. Install the upper camshaft bearing shells and apply engine oil to them.

9. Apply sealant to the bearing caps in the indicated locations.

10.

NOTE: The arrows on the camshaft bearing caps must point toward the front of the engine.

NOTE: Tighten the camshaft bearing caps, working evenly, one turn at a time.

Install the camshaft.

1. Install the brake vacuum pump plunger.
2. Install camshaft bearing caps No.1, 3 and 5 and tighten the nuts by hand.
3. Install the remaining camshaft bearing caps and tighten the nuts finger tight.