303-01D Engine - 2.

3L EcoBoost (257kW/350PS) - MI4 2016 Focus

Removal and Installation Procedure revision date: 01/17/2018

Cylinder Head

Base Part Number: 6051

Special Tool(s) / General Equipment

Oil Drain Equipment

Removal

1. With the vehicle in NEUTRAL, position it on a hoist.

Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).

2. Remove the cowl panel grille.

Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).

3. NOTICE: Do not pull the engine appearance cover forward or sideways to remove. Failure to press
straight upward on the underside of the cover at the attachment points may result in damage to the cover
or engine components.

1. Place your hand under the engine appearance cover at each grommet location and push straight up to
release each grommet from the studs.
2. After all of the grommets have been released from the studs, remove the appearance cover from the
engine.

4. Release the fuel system pressure.

Refer to: Fuel System Pressure Release (310-00D Fuel System - General Information - 2.3L EcoBoost
(257kW/350PS) - MI4, General Procedures).

5. Remove the battery tray.

Refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation).
6. Drain the cooling system.
Refer to: Cooling System Draining, Vacuum Filling and Bleeding (303-03D Engine Cooling - 2.3L EcoBoost
(257kW/350PS) - MI4, General Procedures).

7. Remove the following items:

1. Remove the intake manifold.
Refer to: Intake Manifold (303-01D Engine - 2.3L EcoBoost (257kW/350PS) - MI4, Removal and
Installation).
2. Remove the camshafts.
Refer to: Camshafts (303-01D Engine - 2.3L EcoBoost (257kW/350PS) - MI4, Removal and Installation).

8. Remove and discard the turbocharger nuts.

9. Remove and discard the upper cylinder head studs.

10.
Detach and disconnect the fuel rail electrical connector.
Detach the wiring harness retainers.
Remove the fuel rail insulator shield.

11. Disconnect the fuel injector and the FRP sensor electrical connectors.
12. Remove the bolt and ground wire.

13. Disconnect the CHT sensor wiring harness electrical connector.

14. Remove the bolts and position the water outlet aside.

15. NOTE: If the camshafts and valve tappets are to be reused, mark the location of the valve tappets to make sure
they are assembled in their original positions.

Remove the valve tappets.

16.
Remove the cylinder head bolts.
Discard the bolts.

17. NOTICE: When removing or installing the cylinder head, use care to prevent excessive movement of the
turbocharger. Excessive movement may cause damage to the turbocharger oil return tube resulting in an
engine oil leak.

1. Lift the cylinder head to clear the locating dowels in the cylinder block.
2. Slide the cylinder head and studs out of the turbocharger and remove.

Click here to view a video version of this procedure.

18. Remove and discard the lower cylinder head studs and turbocharger gasket.

19. Remove and discard the cylinder head gasket.

20. NOTICE: 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 that make leak paths. Use a plastic
 scraping tool to remove all traces of the head gasket.

NOTE: Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material
is removed.

Clean the cylinder head sealing surfaces.

21. Inspect the cylinder head sealing surfaces.

22.
Check the cylinder head distortion.
Refer to: Cylinder Head Distortion (303-00 Engine System - General Information, General Procedures).
Check the cylinder block distortion.
Refer to: Cylinder Block Distortion (303-00 Engine System - General Information, General Procedures).

23. NOTE: Replace gasket if damaged.

Inspect the coolant outlet gasket and replace as necessary.

Installation

1. Install the new lower cylinder head studs and new turbocharger gasket.
Torque: 150 lb.in (17 Nm)

2. Install the new cylinder head gasket.

3. NOTICE: When removing or installing the cylinder head, use care to prevent excessive movement of the
turbocharger. Excessive movement may cause damage to the turbocharger oil return tube resulting in an
engine oil leak.

1. Slide the cylinder head and studs into the turbocharger.

2. Align the cylinder head to the locating dowels in the cylinder block and install.

Click here to view a video version of this procedure.

4. Install the new cylinder head bolts and tighten in sequence shown.
Torque:
Stage 1: 62 lb.in (7 Nm)
Stage 2: 133 lb.in (15 Nm)
Stage 3: 41 lb.ft (55 Nm)
Stage 4: 90°
Stage 5: 90°

5. NOTE: Make sure that the components are installed to the position noted before removal.

Lubricate with clean engine oil and install the valve tappets.

6. Position the water outlet and install the bolts.

Torque: 89 lb.in (10 Nm)
7. Connect the CHT sensor wiring harness electrical connector.

8. Position the ground wire and install the bolt.

Torque: 106 lb.in (12 Nm)
 9. Connect the fuel injector and the FRP sensor electrical connectors.

10.
Install the fuel rail insulator shield.
Attach the wiring harness retainers.
Connect and attach the fuel rail electrical connector.
11. Install the new upper cylinder head studs.
Torque: 150 lb.in (17 Nm)

12.
1. Install the new lower turbocharger nuts.
Torque: 37 lb.ft (50 Nm)
2. Install the new upper turbocharger nuts.
Torque: 37 lb.ft (50 Nm)
13. Install the following items:
1. Install the camshafts.
Refer to: Camshafts (303-01D Engine - 2.3L EcoBoost (257kW/350PS) - MI4, Removal and Installation).
2. Install the intake manifold.
Refer to: Intake Manifold (303-01D Engine - 2.3L EcoBoost (257kW/350PS) - MI4, Removal and
Installation).

14. NOTE: Be prepared to collect escaping fluid.

Remove the oil pan drain bolt and drain the engine oil.
Use the General Equipment: Oil Drain Equipment
Install the oil pan drain bolt.
Torque: 20 lb.ft (27 Nm)
15. Remove and discard the engine oil filter.
Use the General Equipment: Oil Drain Equipment

16. NOTE: Component must be lubricated with clean engine oil.

Lubricate the oil filter seal with clean engine oil and install.
Torque:
Stage 1: 71 lb.in (8 Nm)
Stage 2: 180°
17. NOTE: Make sure that fluid level is to the MAX mark.

Refer to: Specifications (303-01D Engine - 2.3L EcoBoost (257kW/350PS) - MI4, Specifications).

18.

1. NOTE: Lubricating the grommets with silicone grease will aid in the installation of the engine appearance
cover, and any future removal and installation of the cover.

Lubricate each grommet with silicone grease.

2. Position the engine appearance cover onto engine with the grommets aligned with the studs.
 3. Press down on the engine appearance cover at each grommet location to attach the grommets onto the
studs.

19. Install the battery tray.

Refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation).

20. Fill the cooling system.

Refer to: Cooling System Draining, Vacuum Filling and Bleeding (303-03D Engine Cooling - 2.3L EcoBoost
(257kW/350PS) - MI4, General Procedures).

21. Install the cowl panel grille.

Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).

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