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303-01B Engine - 1.6L Zetec-E (Zetec)-1.8L Zetec-E (Zetec)-2.0L Zetec-E (Zetec)|Engine > < Engine - Vehicles With: 4-Speed Automatic Transmission (4F27E)

Focus 1999 (08.1998-12.2004)

Engine - 1.6L Zetec-E (Zetec)/1.8L Zetec-E (Zetec)/2.0L Zetec-E (Zetec) - Engine—1.6L Zetec-E (Zetec) Focus 1999 (08/1998-12/2004)
Installation

Special Tool(s)

Lifting bracket, engine

303-122 (21-068A)

Radiator hose clamp remover/installer

303-397 (24-003)
General Equipment
Assembly table
Retaining strap
Engine hoist
Wooden blocks
Materials
Name
Specification
High-temperature grease
ESD-M1C220-A 

Installation

All vehicles
NOTE:
NOTE:If necessary, use Special Tool 303-397 to install coolant and ventilation hoses.
  1. Using a retaining strap, and wooden blocks secure the transaxle on the assembly stand.

  1. Using a suitable engine hoist align the engine to the transaxle.

  1. Install the transaxle right-hand retaining bolts.
    1. Flange bolts.
    1. Starter motor bolts.
    1. Attach the ground cable.

  1. Install the lower transaxle retaining bolts.

  1. Install the transaxle left-hand retaining bolts.

  1. Install the starter motor and tighten the flange bolt.
    1. Starter motor bolt.
    1. Flange bolt.
  1. Raise the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Position the engine and transaxle assembly on the assembly stand below the vehicle.
    • Carefully lower the vehicle.

  1. NOTE:
    NOTE:Do not full tighten the bolts and nuts at this stage.
    Install the engine front mount.

  1. NOTE:
    NOTE:Do not full tighten the bolts and nuts at this stage.
    Install the engine rear mount.

  1. CAUTION:
    CAUTION:If brake fluid is spilt on the paintwork the affected area must be immediately washed down with cold water.
    Attach the clutch slave cylinder supply line.
  1. Remove the retaining strap from the transaxle.
  1. Raise the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.
    • Remove the assembly stand.

  1. Install the engine support insulator.

  1. Connect the vehicle speed sensor (VSS) electrical connector.

  1. CAUTION:
    CAUTION:The inner joint must not be bent at more than 18 degrees. The outer joint must not be bent at more than 45 degrees.
    NOTE:
    NOTE:Use new nuts and a new center bearing cap.
    Install the right-hand front halfshaft and the intermediate shaft.

  1. NOTE:
    NOTE:Make sure the snap-ring is correctly located.
    Install the left-hand front halfshaft.

  1. CAUTION:
    CAUTION:Make sure the heat shield is installed to prevent damage to the ball joint.
    Attach the lower arm ball joint to the wheel knuckle on both sides.
    1. Install the lower arm ball joint.
    1. Install the retaining bolt.

  1. Install the exhaust flexible pipe.
  1. Install the front wheels and tires. For additional information, refer to Section  204-04 Wheels and Tires.

  1. Tighten the engine rear mount retaining nuts and bolts.

  1. Tighten the engine rear mount retaining nuts.
  1. Raise the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Install the power steering pump lower retaining bolts.

  1. Connect the coolant pump hose.
Vehicles with air conditioning

  1. Attach the air conditioning compressor to the engine.
All vehicles
  1. Install the accessory drive belt. (vehicles without air conditioning shown).
    • Rotate the belt tensioner in a clockwise direction.

  1. Install the accessory drive belt cover.

  1. Attach the gearshift and selector cables to the transaxle.
    • Turn the abutment collar clockwise onto the bracket.

  1. Close the gearshift and selector cables cover.

  1. Connect the reversing lamp switch, crankshaft position sensor (CKP) and heated oxygen sensor (HO2S) electrical connectors.
    • Attach the wiring harness to the engine.

  1. Install the air deflector and the radiator fan.
    • Position the air deflector and clip on at the top on both sides (left-hand side shown).
  1. Lower the vehicle.

  1. Attach the coolant hoses to the engine.

  1. Connect the fuel lines and the ground cable to the manifold.

  1. Connect the brake servo vacuum hose.

  1. Connect the vacuum hoses to the throttle body.

  1. Connect the engine wiring harness electrical connector.

  1. Connect the generator electrical connector.

  1. CAUTION:
    CAUTION:If brake fluid is spilt on the paintwork the affected area must be washed down with cold water.
    Attach the clutch slave cylinder supply line.
    • Attach the spring clip.

  1. Connect the radiator fan electrical connector.
    • Install new cable ties.

  1. Connect the powertrain control module (PCM) electrical connector.
    • Install new cable ties.

  1. Connect the power steering pressure (PSP) switch electrical connector.

  1. Connect the EI coil and the radio interference filter electrical connectors.

  1. Attach the accelerator cable to the throttle body.
    1. Hook the cable in place.
    1. Engage the plastic clip.

  1. Attach the headlamp ground cable.

  1. Install the air cleaner housing.
    1. Connect the mass air flow (MAF) sensor electrical connector.
    1. Connect the air breather pipe to the air cleaner.
    1. Connect the air cleaner outlet tube to the throttle body.

  1. Tighten the strut and spring assembly top mount retaining nuts on both sides.

  1. Install the power steering pump upper retaining bolts.

  1. Attach the power steering line to the engine.

  1. Attach the power steering fluid reservoir to the wheelhouse assembly.

  1. Attach the coolant expansion tank to the wheelhouse assembly.

  1. Remove the special tool.

  1. Connect the traction control and heated seats electrical connectors (if equipped).

  1. Attach the gearshift lever trim to the floor console.

  1. Attach the gearshift lever boot to the floor console.
  1. Install the battery tray. For additional information, refer to Section  414-01 Battery, Mounting and Cables.
  1. Top up the coolant. For additional information, refer to Section  303-03 Engine Cooling.
  1. Check the level of the transaxle fluid and top up as necessary. For additional information, refer to Section  308-03A Manual Transmission/Transaxle / 308-03B Manual Transmission/Transaxle / 308-03D Manual Transmission/Transaxle.
  1. Bleed the hydraulic clutch operating system. For additional information, refer to Section  308-03A Manual Transmission/Transaxle / 308-03B Manual Transmission/Transaxle / 308-03D Manual Transmission/Transaxle.

303-01B Engine - 1.6L Zetec-E (Zetec)-1.8L Zetec-E (Zetec)-2.0L Zetec-E (Zetec)|Engine > < Engine - Vehicles With: 4-Speed Automatic Transmission (4F27E)