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HOMESERVICE MANUALSFORD2004FOCUS ZX3, 2.3 Z, STANDARDREPAIR AND DIAGNOSISENGINE MECHANICALMECHANICALENGINE - 2.3LIN-VEHICLE REPAIRVALVE COVERINSTALLATION
2004 Ford Focus ZX3, 2.3 Z, Standard

Valve Cover: Installation

2004 Ford Focus ZX3, 2.3 Z, StandardSECTION Installation
  1. Inspect the valve cover gaskets for damage. Install new gaskets if necessary.
    Fig 1: Inspecting Valve Cover Gaskets
    G04035420Courtesy of FORD MOTOR CO.
  2. Install the valve cover and bolts. Tighten the bolts in the sequence shown.
    Fig 2: Installing Valve Cover And Bolts
    G04035421Courtesy of FORD MOTOR CO.
  3. Reposition the fuel injection supply wiring harness.
    Fig 3: Positioning Fuel Injection Supply Wiring Harness
    G04035422Courtesy of FORD MOTOR CO.
  4. Install the bracket and bolt.
    • Install the two wire connectors on the bracket.
    Fig 4: Installing Wire Connectors On Bracket
    G04035423Courtesy of FORD MOTOR CO.
  5. Connect the upper HO2S electrical connector.
    Fig 5: Connecting Upper Ho2S Electrical Connector
    G04035424Courtesy of FORD MOTOR CO.
  6. Connect the fuel injector electrical connectors.
    Fig 6: Connecting Fuel Injector Electrical Connectors
    G04035425Courtesy of FORD MOTOR CO.
  7. Connect the fuel pressure regulator electrical connector and the vacuum hose.
    Fig 7: Connecting Fuel Pressure Regulator Electrical Connector And Vacuum Hose
    G04035426Courtesy of FORD MOTOR CO.
  8. Install the wiring harness retainers on the valve cover studs.
    Fig 8: Installing Wiring Harness Retainers On Valve Cover Studs
    G04035427Courtesy of FORD MOTOR CO.
  9. Install the breather tube on the valve cover.
    Fig 9: Installing Breather Tube On Valve Cover
    G04035428Courtesy of FORD MOTOR CO.
  10. Install the coil-on-plug assemblies.
      NOTE: Push the coil assemblies down firmly until the boot seal has sealed the access hole.
    1. Install the coil assemblies.
    2. Install the coil assembly bolts.
    Fig 10: Installing Coil Assembly Bolts
    G04035429Courtesy of FORD MOTOR CO.
  11. Connect the ignition coil electrical connectors.
    Fig 11: Connecting Ignition Coil Electrical Connectors
    G04035430Courtesy of FORD MOTOR CO.
  12. Connect the cylinder head temperature (CHT) sensor electrical connector.
    Fig 12: Connecting Cylinder Head Temperature Sensor Electrical Connector
    G04035431Courtesy of FORD MOTOR CO.
  13. Position the CHT boot.
    Fig 13: Positioning CHT Boot
    G04035432Courtesy of FORD MOTOR CO.
  14. Connect the camshaft position (CMP) sensor electrical connector.
    Fig 14: Connecting Camshaft Position Sensor Electrical Connector
    G04035433Courtesy of FORD MOTOR CO.
  15. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.