What all must be done to swap a Focus 2.0L Split port head onto a '98 Escort 2.0 SPI engine? I want to replace mine with a new improved casting from enginequest but they only make one for the Focus. I know the intake manifold bolt pattern is different so I will have to change it but is their going to be any issues with Cam timing/sensor alignment?

 

For anyone looking to try this, I believe it will work if you change the intake manifold and intake manifold runner butterfly valve assembly. The only major change i can find is the Escort head uses 8 bolts and the Focus head uses 7 bolts and it is not the same pattern. The only other issue is the timing cover, the Focus is not set up for the same cover as the Escort and I dont think you can use the one for the Focus on the Escort without some mods but not sure. You can reuse the Escort cover as the lower bolts go into the waterpump and they will hold it on to keep fingers and such out of the belt, there is just no place for the upper bolts.
The new head arrived last week and comes bare so you will have to reuse your old camshaft, valves, springs, retainers and locks as weel as rocker arms. the head will also have to have the valves from your old head lapped in and seated to the new head (valve job from your local macine shop).My engine block is at the machine shop being decked and should be back next week and I will start putting it back together. If i find any other issues I will post them for you.
One other piece of info I found was that the Ford factory supposedly changed the valve seats in 2002 to improve the durability, I can not vouch for this but if true you could get everything to do this swap from a 02 or newer Focus from a salvage yard such as a u-pull-it for fairly cheap. If you go this way make sure to have the head resurfaced and checked for cracks before you install it. Also check the engine block deck surface for warpage, that is what caused my problem to start with.