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Ford Workshop Service and Repair Manuals

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Engine - Vehicles With: 4-Speed Automatic Transmission (4F27E) > < Engine - Vehicles With: 5-Speed Manual Transmission (iB5)

Focus 1999 (08.1998-12.2004)

Engine - 1.6L Zetec-E (Zetec)/1.8L Zetec-E (Zetec)/2.0L Zetec-E (Zetec) - Engine—Vehicles With: 5-Speed Manual Transmission (MTX-75) Focus 1999 (08/1998-12/2004)
Removal

Special Tool(s)

Remover, front drive halfshaft

308-192 (16-057)

Aligner, gearshift lever neutral position

308-273 (16-088A)

Lifting bracket, engine

303-122 (21-068A)

Radiator hose clamp remover/installer

303-397 (24-003)
General Equipment
Auxiliary plugs
Assembly table
Retaining strap
Workshop hoist
Wooden blocks
Materials
Name
Specification
Cable ties
 

Removal

All Vehicles
  1. General remarks.
    • The positions of the engine mounting and the engine roll restrictor are described looking from the transmission towards the engine.
    • If necessary, use Special Tool 303-397 to remove coolant and ventilation hoses.
    • Owing to special model variants, some job steps do not apply to all vehicles. These are clearly marked in the text.
    • If necessary, separate the cable ties and renew on installation.
  1. Standard preparatory measures
    • Make a note of the radio keycode.
    • Make a note of the preset radio stations.
  1. WARNING:
    WARNING:To prevent the risk of scalding, place a thick cloth over the filler cap before opening the cooling circuit. Failure to do so can result in injury.
    Open the coolant expansion tank.

  1. CAUTION:
    CAUTION:Disconnect the battery positive and negative leads. Remove the battery.
    Remove the battery tray and detach the ground lead.
    1. Unclip and separate the connector.
    1. Unclip the wiring harness.
    1. Unscrew the bolts.
    1. Detach the positive and negative leads.

  1. Remove the air cleaner housing.
    1. Pull off the plug of the mass air flow (MAF) sensor.
    1. Detach the PCV hose.
    1. Detach the intake hose.
    • Remove the air cleaner housing from the rubber bush.

  1. Detach the ground lead.

  1. Remove the intake tube.

  1. NOTE:
    NOTE:The resonator is a push fit in the bracket.
    Remove the air cleaner intake with resonator.

  1. WARNING:
    WARNING:Danger of scalding if the engine is warm.
    Drain the coolant (shown from below).
    • Screw the drain plug back in after draining.

  1. NOTE:
    NOTE:Stop from turning using an Allen key.
    Slacken the suspension strut nuts by five turns on both sides.

  1. Loosen the wheel nuts of the left and right-hand front wheels.

  1. Lock the driver's gear shift lever using the special tool.
    • Move the shift lever to neutral.
    • Detach the shift lever cover and insert the special tool.

  1. Detach the accelerator cable.
    1. Unhook the cable.
    1. Pull off the plastic clip and lay the accelerator cable to one side.

  1. Pull off the connectors of the EI coil and the radio interference filter.

  1. Separate the heated oxygen sensor (HO2S) connector and the power steering pump pressure switch connector.

  1. Disconnect the radiator fan plug.
    • Separate the cable ties.

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

  1. Pull off the generator connector.

  1. WARNING:
    WARNING:Escaping brake fluid. Do not allow brake fluid to come into contact with the skin or eyes. If brake fluid should come into contact with your skin or eyes, rinse the affected area immediately with water.
    CAUTION:
    CAUTION:If any brake fluid gets on the paintwork wash it off immediately with water.
    Detach the high-pressure pipe from the clutch slave cylinder.
    • Pull out the clip.
    • Pull out the high-pressure pipe and tie it up with cable ties.

  1. Separate the harness connector.

  1. Disconnect the plug of the vehicle speed sensor (VSS)

  1. Disconnect the plug for the reversing lamp switch and the crankshaft position sensor (CKP sensor).
    • Unclip the wiring loom from the engine.

  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. Pull off the low pressure hoses.

  1. Detach the brake servo vacuum hose.
  1. Release the fuel pressure. For additional information, refer to Subsection 310-00.

  1. WARNING:
    WARNING:Escaping fuel. Observe the safety regulations for working with fuel.
    Detach the fuel pipes.
    • Detach the ground lead.

  1. Detach the coolant hoses.

  1. Detach the shift cable and selector cable from the transmission.
    1. Detach the shift cable from the gear lever.
    1. Pretension the abutment collars by turning them in an anti-clockwise direction and remove the cable assembly from the bracket.
    1. Detach the selector cable from the selector lever.
    1. Pretension the abutment collars by turning them in an anti-clockwise direction and remove the cable assembly from the bracket.
    1. Undo the adjustment mechanism by pressing it in.
  1. Raise the vehicle. For additional information, refer to Subsection 100-02.

  1. Remove the drive belt cover.

  1. Slacken the drive belt and remove it (vehicle without air conditioning shown).
    • Turn the belt tensioner clockwise.
Vehicles with air conditioning
  1. Detach the air conditioning compressor and tie it up on the radiator crossmember.
All vehicles
  1. Detach the coolant hose and remove the bolts of the power steering pump.
  1. Lower the vehicle.

  1. Detach the coolant expansion tank and lay it to one side.

  1. Remove the PAS reservoir and lay it to one side.

  1. Detach the bracket of the power steering high-pressure pipe.

  1. Detach the power steering pump and tie it up with cable ties.
  1. Raise the vehicle. For additional information, refer to Subsection 100-02.

  1. Remove the flexible exhaust pipe.

  1. Remove the engine roll restrictor.

  1. Detach both suspension arms (left-hand side shown).
  1. Detach both front wheels.

  1. CAUTION:
    CAUTION:The inner joint must not be bent at more than 18°; the outer joint must not be bent at more than 45°.
    Detach the right-hand front drive halfshaft with intermediate shaft.
    • Detach the intermediate shaft bearing cap.
    • Discard the nuts and bearing cap.
    • Pull the intermediate shaft with front drive halfshaft from the transmission and tie up with cable ties.
    • Close off the transmission with auxiliary plugs.

  1. CAUTION:
    CAUTION:The inner joint must not be bent at more than 18°; the outer joint must not be bent at more than 45°.
    Detach the left-hand front drive halfshaft from the transmission using the special tool.
    • Pull out the front drive halfshaft and tie up with cable ties.
    • Close off the transmission with auxiliary plugs.
  1. Put the assembly table with wooden blocks on it under the vehicle.
  1. Carefully lower the vehicle until the engine and transmission assembly is on the assembly stand.

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

  1. Remove the rear engine mounting.

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

  1. Hook the engine and transmission assembly into the jib crane.

  1. Remove the starter motor and ground lead.

  1. Remove the flange bolts.

  1. Remove the flange bolts (continued).

Engine - Vehicles With: 4-Speed Automatic Transmission (4F27E) > < Engine - Vehicles With: 5-Speed Manual Transmission (iB5)