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Home >> Ford >> 2000 >> ZX2 Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1326 (Engine - SVT) >> General Procedures >> Valve Clearance >> Adjust

Valve Clearance: Adjust

WARNING: This page is about a different car, the 2004 Ford Focus. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Exchange the tappets to correct the valve clearance.
  1. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
    2. NOTE: Do not remove the timing belt upper cover at this stage.
    Fig 1: Removing Timing Belt Upper Cover Retaining Bolts
    G04034902Courtesy of FORD MOTOR CO.
  2. Remove the timing belt upper cover retaining bolts.
  3. Disconnect the variable camshaft timing (VCT) valve electrical connector.
    Fig 2: Disconnecting Variable Camshaft Timing Valve Electrical Connector
    G04034903Courtesy of FORD MOTOR CO.
    4. CAUTION: Do not pull the spark plug connectors by the ignition wires when removing them. If necessary pull off the ignition wires from the ignition coils to prevent kinking the ignition wires. Slightly twist the spark plug connectors before removing them in order to loosen the seals.
    CAUTION: Pull off the spark plug connectors in line with the spark plugs.
    NOTE: Loosening sequence: from the outside to the inside, working diagonally.
    Fig 3: Removing Valve Cover
    G04034904Courtesy of FORD MOTOR CO.
  4. Remove the valve cover.
    1. Disconnect the spark plug electrical connectors.
    2. Disconnect the positive crankcase ventilation (PCV) hose from the valve cover.
    3. Remove the bolts.
    5. CAUTION: Only rotate the crankshaft in the normal direction of rotation.
    Fig 4: Identifying Crankshaft Piston No. 1 At Top Dead Center (TDC)
    G04034905Courtesy of FORD MOTOR CO.
  5. Rotate the crankshaft until piston No. 1 is at top dead center (TDC).
    6. NOTE: Note down each cylinder number and the valve clearances measured.
    NOTE: Only rotate the crankshaft in the normal direction of rotation.
    Fig 5: Measuring Valve Clearance
    G04034906Courtesy of FORD MOTOR CO.
  6. Using a suitable set of feeler gauges, measure the valve clearance.
    • Permitted valve clearance: inlet (0.21 - 0.29 mm)
    • Permitted valve clearance: exhaust (0.32 -0.40 mm)
    • Rotate the crankshaft a further 180 degrees. In this instance, the measuring sequence follows the firing order 1-3-4-2.
    7. NOTE: Only carry out the following steps when the valve clearance(s) require adjustment.
  7. Remove the camshafts. For additional information, refer to CAMSHAFTS .
    8. NOTE: Aim to set the valve clearance to the middle of the range (inlet 0.25 mm; exhaust 0.36 mm)
    NOTE: The number on the valve tappet indicates the valve tappet thickness.
  8. Determine the tappet thickness required.
    • Remove the valve tappet and read the thickness from the underside.
    • Calculate the valve tappet thickness required and insert the correct tappet.
      • Inlet valves: tappet thickness required = thickness of currently installed tappets + measured valve clearance - 0.25 mm.
      • Exhaust valves: tappet thickness required = thickness of currently installed tappets + measured valve clearance - 0.36 mm.
    9. CAUTION: Rotate the crankshaft until piston No. 1 is approximately 25 mm before TDC (BTDC).
    NOTE: Do not install the timing belt at this stage.
  9. Install the camshafts. For additional information, refer to CAMSHAFTS .
    10. NOTE: Rotate the camshafts to measure the valve clearance.
  10. Recheck the valve clearance.
  11. Install the timing belt. For additional information, refer to TIMING BELT .
    12. NOTE: Apply silicone grease to the inside of the spark plug connectors to a depth of 5-10 mm.
    Fig 6: Installing Valve Cover
    G04034907Courtesy of FORD MOTOR CO.
  12. Install the valve cover.
    1. Install the valve cover retaining bolts
      • Tighten the retaining bolts in two stages.
      • Stage 1: 2 Nm
      • Stage 2: 7 Nm
    2. Connect the PCV hose to the valve cover.
    3. Connect the spark plug electrical connectors.
  13. Connect the VCT valve electrical connector.
    Fig 7: Connecting VCT Valve Electrical Connector
    G04034908Courtesy of FORD MOTOR CO.
    14. NOTE: Check that the gasket on the upper timing belt cover is seated correctly and adjust if necessary.
    Fig 8: Installing Timing Belt Upper Cover Retaining Bolts
    G04034909Courtesy of FORD MOTOR CO.
  14. Install the timing belt upper cover retaining bolts.
  15. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
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