1. Gather Tools and Materials:
* New valve cover gasket: Get a genuine Ford gasket or a high-quality aftermarket equivalent. Don't skimp here; a poor-quality gasket will leak.
* Socket set (metric): You'll need various sizes, including those for the valve cover bolts.
* Wrench set (metric): May be needed for stubborn bolts or other fasteners.
* Torque wrench: Crucial for tightening the valve cover bolts to the correct specification. Over-tightening can warp the valve cover or crack the cylinder head.
* Pliers: For disconnecting electrical connectors.
* Screwdrivers (Phillips and possibly flathead): For various fasteners and possibly the PCV valve.
* Shop rags or paper towels: To clean up oil spills.
* Valve cover gasket sealant (optional but recommended): A thin bead of high-temperature RTV silicone sealant applied to the gasket helps prevent leaks.
* Drain pan: To catch any spilled oil.
* Clean work area: A clean, well-lit space is essential.
* Repair manual: Specific to your 2001 Ford Focus engine. This is highly recommended.
2. Preparation:
* Disconnect the battery negative terminal. This is crucial for safety.
* Warm up the engine slightly: This will thin the oil, making it easier to drain. Don't overheat it.
* Locate the valve cover: It's the topmost part of the engine, usually made of aluminum.
3. Removal:
* Locate and disconnect all electrical connectors attached to the valve cover. These are usually for things like the camshaft position sensor (CMP) and ignition coils. Take pictures or make notes of their locations for reassembly.
* Remove the spark plug wires carefully and keep track of their order (1, 2, 3, 4). Number them if necessary.
* Remove the valve cover bolts. These are usually located around the perimeter of the valve cover. Loosen them slightly before removing them completely.
* Carefully lift off the valve cover. Be gentle; the old gasket may stick to either the valve cover or the cylinder head. Take note of the gasket's orientation and any potential alignment dowels.
* Clean the valve cover and cylinder head mating surfaces. Use a clean rag and a solvent like brake cleaner (be careful around electrical components) to remove any old gasket material, oil, or debris. Ensure both surfaces are completely clean and dry.
4. Installation:
* Apply a thin, even bead of RTV sealant to the new gasket. Follow the manufacturer's instructions on the sealant. Don't use too much.
* Carefully install the new gasket onto the cylinder head. Make sure it sits correctly in the groove.
* Carefully lower the valve cover onto the cylinder head, ensuring it's properly aligned.
* Tighten the valve cover bolts in a crisscross pattern. Use your torque wrench and follow the torque specifications in your repair manual precisely. Don't over-tighten.
5. Reassembly:
* Reconnect all the spark plug wires in the correct order.
* Reconnect all the electrical connectors.
* Double-check all connections and bolts.
6. Final Checks:
* Start the engine and check for leaks. Look closely around the valve cover for any signs of oil leakage.
* Check the oil level. Top it off if necessary.
Important Considerations:
* Engine type: The process can vary slightly depending on whether you have a Zetec or Duratec engine. Consult your repair manual.
* PCV valve: The PCV (Positive Crankcase Ventilation) valve may be integrated into the valve cover. You may need to replace it if it's damaged or clogged.
* Safety: Always prioritize safety. Wear safety glasses and gloves. Work in a well-ventilated area.
This is a general guide. A repair manual specific to your 2001 Ford Focus will provide detailed instructions and diagrams. If you're uncomfortable performing this repair, it's best to take your vehicle to a qualified mechanic. Improper repair can lead to significant engine damage.
