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Old 01-29-2005, 09:26 PM   #1
Focus Jr. Enthusiast
Join Date: Jul 2004
Fan#: 10891
Location: Oregon
What I Drive: 2002 Loaded Graber Green SE

Posts: 46
FF Reputation: 1 Frag2win Good Standing Member
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Post Valve bucket clearance (Valve adjustment)

This is long winded! But will help other Focus Do it yourselfers out there.
If you have no clue or just think you know what you are doing dont do this!

80,0000 and valves are rattling! "Not injectors"
Ford workshop manual says:

Mechanical bucket tappet
The level of wear is so minimal that initial checking and adjustment of the valve clearance is not necessary until 150,000 km (90,000 miles)

Well I dont have a lead foot! <-----B.S.
Theres a black hole Under gas pedal it just always sucks my foot to floor! <-- Treckie excuse!
But I do drive it hard! Not Abuse! Just Hard! I know the higher RPM's / engine stress will cause more wear.

So im gonna check clearance first.
If it needed get new buckets then insert a later day.

The 4 Questions I have are.

1) Should the motor be cold or warm?

2) Does the Focus have issues with head gaskets? (Good time for gasket and belts)
Will probably wait till get chips then get dremil happy polish the ports.
Also take head down a little.

3) Does the Focus crank do 2 revs between tdc to tdc? Forget it Section 5-1 180 degrees then next cylinder. 180 x 4 = 720 DAMN im smart.

4) Does anyone know what the stock motors compresion test range is (100-125)?

Thanks To CKA I can share this info.

This is out of the 2002 Ford workshop manual.

From here below is all service manual.

Valve Clearance

1. CAUTION: Exchange the tappets to correct the valve clearance.

CAUTION: Disconnect the battery ground cable.
NOTE: Do not remove the upper timing belt cover.
Undo the bolts in the upper timing belt cover.

2. 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.

Remove the cylinder head cover.
1. Pull off the spark plug connectors.
2. Detach the crankcase ventilation hose.
3. Unscrew the 10 bolts.

3. CAUTION: Only rotate the engine on the crankshaft and in its rotation direction.
Set the engine to TDC on cylinder number 1.

4. NOTE: Note down each cylinder number and the valve clearances measured.

Measure the valve clearance using feeler gauges.
Permitted valve clearance: inlet (0.11 - 0.18 mm)
Permitted valve clearance: exhaust (0.27 - 0.34 mm)

5. CAUTION: Only rotate the engine on the crankshaft.

Measure the valve clearance (continued).
1.Rotate the engine a further 180 degrees on the crankshaft in its rotation direction. In this instance, the measuring sequence follows the firing order 1-3-4-2.
2.Repeat the previous steps for the other cylinders.

6. NOTE: Only carry out the following steps when the valve clearance must be adjusted.
NOTE: Aim to set the valve clearances to the middle of the range (inlet 0.15 mm; exhaust 0.30 mm)

Remove the camshafts.
7. NOTE: The number on the tappet indicates the tappet thickness.
Determine the tappet thickness required.
1. Remove the adjusting tappet and read the thickness from the back side.
2. Determine the tappet thickness required and insert the correct tappet.
3. Inlet valves: tappet thickness required = thickness of currently installed tappet
+measured valve clearance - 0.15 mm.
4.Exhaust valves: tappet thickness required = thickness of currently installed tappet + measured valve clearance - 0.30 mm.

8. CAUTION: Set the piston on cylinder number 1 to approximately 25 mm before TDC.
Install the camshafts and camshaft timing belts. For additional information, refer to Camshaft.

9. NOTE: Turn the camshaft to measure the valve clearance.
NOTE: Do not attach the timing belt until the setting is in order.
Recheck the valve clearance after adjustment is complete.

10. Install the timing belt. For additional information, refer to Timing Belt.

11. CAUTION: Use a blunt object (a plastic cable tie) to apply the silicone grease, to avoid damaging the spark plug connectors.
CAUTION: Push on the spark plug connectors, keeping them in line with the spark plugs.
NOTE: Apply silicone grease to the inside of the spark plug connectors to a depth of 5-10 mm.
Install the cylinder head cover.
1. Insert the 10 bolts and tighten them in two stages.
2. Stage 1: 2 Nm.
3. Stage 2: 7 Nm.
4. Attach the crankcase ventilation hose.
5. Fit the spark plug connectors and make sure that they engage correctly.

12. NOTE: Check that the gasket on the upper timing belt cover is seated correctly and adjust if necessary.
Install the upper timing belt cover.

13. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.
Connect the battery ground cable.

14. Check the fluid levels and adjust if necessary.

15. Check that the vacuum hoses and cables are routed correctly and fix in place using


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