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In-vehicle Repair|Disassembly > < 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)
Removal

Special Tool(s)

Lifting bracket, engine

303-122 (21-068A)

Remover, driveshaft

308-237 (16-087)

Radiator hose clamp remover/installer

303-397 (24-003)

Aligner gearshift

307-350A (16-088)
General Equipment
Auxiliary plugs
Assembly table
Retaining strap
Engine hoist
Wooden blocks

Removal

All vehicles
  1. Release the fuel system pressure. For additional information, refer to Section  310-00A Fuel System - General Information / 310-00B Fuel System - General Information / 310-00C Fuel System - General Information.
  1. Remove the battery tray. For additional information, refer to Section  414-01 Battery, Mounting and Cables.

  1. Remove the air cleaner housing.
    1. Disconnect the mass air flow (MAF) sensor electrical connector.
    1. Disconnect the air breather pipe from the air cleaner.
    1. Disconnect the air cleaner outlet tube from the throttle body.
    • Remove the air cleaner housing from the rubber bush.

  1. Disconnect the headlamp ground cable.

  1. Loosen the strut and spring assembly top mount retaining nuts by five turns on both sides (left-hand side shown).

  1. Detach the gearshift lever boot from the floor console.

  1. Detach the gearshift lever trim panel from the floor console.
    • Detach the retaining clips.

  1. Remove the gearshift lever trim panel.
    • Disconnect the traction control electrical connector (if equipped).
    • Disconnect the heated seats electrical connector(s) (if equipped).

  1. NOTE:
    NOTE:Make sure the gearshift mechanism is in neutral.
    Using the special tool, lock the driver's gearshift lever.

  1. Detach the accelerator cable from the throttle body and position to one side.
    1. Detach the cable.
    1. Disconnect the clip.

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

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

  1. Disconnect the radiator fan electrical connector.
    • Remove the cable ties.

  1. Disconnect the powertrain control module (PCM) electrical connector.

  1. Disconnect the generator electrical connector.

  1. CAUTION:
    CAUTION:If brake fluid is split on the paintwork the affected area must be immediately washed down with cold water.
    Detach the clutch slave cylinder supply line and position it to one side.
    • Detach the spring clip.

  1. Disconnect the engine wiring harness electrical connector.

  1. Remove the air deflector and the radiator fan.
    • Undo the clips on both sides (left side shown).
    • Unhook the air deflector upwards and remove it downwards.

  1. Disconnect the vacuum hoses from the throttle body.

  1. Detach the brake servo vacuum hose.

  1. Disconnect the fuel lines and ground cable from the manifold.

  1. Detach the coolant expansion tank from the wheelhouse assembly and position it to one side.

  1. Detach the power steering fluid reservoir and position it to one side.

  1. Detach the power steering line from the engine.

  1. Remove the power steering pump upper retaining bolts.
  1. Drain the coolant. For additional information, refer to Section  303-03 Engine Cooling.
  1. Remove the front wheels and tires. For additional information, refer to Section  204-04 Wheels and Tires.

  1. Disconnect the reversing lamp switch, crankshaft position sensor (CKP) and the heated oxygen sensor (H02S) electrical connectors.
    • Detach the wiring loom from the engine.

  1. Open the shift and selector cables cover.

  1. Detach the shift and selector cables from the transaxle.
    • Detach the shift and selector cables by turning the abutment collar clockwise.

  1. Remove the accessory drive belt cover.

  1. Remove the accessory drive belt (vehicle without air conditioning shown).
    • Rotate the belt tensioner in a clockwise direction.
Vehicles with air conditioning

  1. Detach the air conditioning compressor from the engine and position it to one side.
    • Using cables ties, secure the air conditioning compressor to the crossmember.
All vehicles
  1. Remove the power steering pump.
    • Using cables ties, secure the power steering pump to the crossmember.

  1. Disconnect the coolant pump hose.
    • Allow the coolant to drain into a suitable container.
  1. Lower the vehicle.

  1. CAUTION:
    CAUTION:Over bending of the exhaust flexible pipe may cause damage resulting in failure.
    CAUTION:
    CAUTION:Support the exhaust flexible pipe with a support wrap or suitable splint.
    Remove the exhaust flexible pipe.
    • Discard the gasket and nuts.

  1. Remove the engine support insulator.

  1. CAUTION:
    CAUTION:Protect the ball joint seal using a soft cloth to prevent damage.
    Detach the lower arm ball joint from the wheel knuckle on both sides.
    • Remove the heat shield.

  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.
    Detach the right-hand front drive halfshaft and intermediate shaft.
    • Detach the intermediate shaft bearing cap.
    • Discard the nuts and bearing cap.
    • Pull the intermediate shaft and the front drive halfshaft from the transaxle and secure to one side with cable ties.
    • Plug the transaxle to prevent oil loss or dirt ingress..

  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.
    Remove the left-hand front drive halfshaft from the transaxle and secure to one side.
    • Plug the transaxle to prevent oil loss or dirt ingress.

  1. Disconnect the vehicle speed sensor (VSS) electrical connector.
  1. Position the assembly stand and suitable wooden blocks under the vehicle.
  1. Carefully lower the vehicle until the engine and transaxle assembly is on the assembly stand.

  1. Detach the coolant hoses from the engine.
    • Allow the coolant to drain into a suitable container.

  1. Secure the engine and transaxle assembly on the assembly stand with a retaining strap.

  1. Remove the rear engine mount.

  1. Remove the front engine mount.
  1. Carefully raise the vehicle.
    • Pull forwards the assembly stand with the engine and transaxle assembly.

  1. Using the special tool, connect the engine and transaxle assembly to the engine hoist.

  1. Remove the transaxle left-hand retaining bolts.
    1. Flange bolts.
    1. Starter motor bolts.
    1. Disconnect the ground cable.

  1. Remove the flange bolt and push the starter motor to one side.
    1. Starter motor bolt.
    1. Flange bolt.

  1. Remove the transaxle right-hand retaining bolts.

  1. Remove the transaxle lower retaining bolts.
  1. With the aid of another technician remove the engine from the transaxle.

In-vehicle Repair|Disassembly > < Engine - Vehicles With: 4-Speed Automatic Transmission (4F27E)