ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

ABOUT US
206-07 Power Brake Actuation|Specifications > < Brake Booster - 2.0L Duratec-RS (Zetec) LHD

Focus RS 2003 (09.2002-)

Power Brake Actuation - Brake Booster—2.0L Duratec-RS (Zetec) RHD Focus RS 2003 (09/2002-)
Removal and Installation

Special Tool(s)

Disconnect Tool, Spring-Lock Coupling 5/8 inch (black)

412-038 (34-003)

Lifting Bracket, Engine

303-122 (21-068A)

General Equipment
Engine hoist
Materials
Name
Specification
Anti-seize grease
SAM-1C9107-A 
Refrigerant oil
WSH-M1C231-B  

Removal

  1. Release the fuel system pressure. For additional information, refer to Section  310-00A Fuel System - General Information.
  1. Evacuate the air conditioning (A/C) system. For additional information, refer to Section  412-00 Climate Control System - General Information.
  1. Remove the master cylinder. For additional information, refer to Section  206-06 Hydraulic Brake Actuation.

  1. Disconnect the electrical connectors from the pedal position switches.
    1. Speed control deactivation switch (if equipped).
    1. Stop lamp switch.
    1. Clutch position switch.

  1. Remove the pedal position switches.
    1. Speed control deactivation switch (colored green) (if equipped).
    1. Stop lamp switch (colored grey).
    1. Clutch position switch (colored red).

  1. Detach the brake booster actuating rod from the brake pedal.
    1. Depress the brake pedal.
    1. Depress the clip.
    1. Remove the brake booster actuating rod pin.

  1. Remove the brake booster retaining nuts.

  1. Detach the wiring harness from the bulkhead.

  1. Detach the brake tubes from the bulkhead.

  1. Detach the power steering reservoir from the wheelhouse assembly and position it to one side.

  1. Remove the fuel line.

  1. Disconnect the air conditioning (A/C) pressure switch electrical connector.
  1. Remove the right-hand front wheel and tire. For additional information, refer to Section  204-04 Wheels and Tires.

  1. Remove the right-hand front fender splash shield.

  1. CAUTION:
    CAUTION:Cap the refrigerant line connections to prevent fluid loss or dirt ingress.
    Using the special tool, disconnect the refrigerant line to the accumulator at the evaporator.
    • Discard the O-rings.

  1. CAUTION:
    CAUTION:Cap the refrigerant line connections to prevent fluid loss or dirt ingress.
    Using the special tool, disconnect the refrigerant line to the condenser at the evaporator.
    • Discard the O-rings.

  1. CAUTION:
    CAUTION:Cap the refrigerant line connections to prevent fluid loss or dirt ingress.
    Remove the refrigerant condenser line.
    • Discard the O-rings.

  1. Detach the refrigerant lines from the wheelhouse assembly.

  1. Remove the refrigerant line retaining bracket.
  1. NOTE:
    NOTE:Pull the refrigerant lines through the hole in the fender.
    Remove the refrigerant lines from the engine compartment.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Remove the engine support insulator centre bolt.

  1. CAUTION:
    CAUTION:Over bending of the flexible pipe may cause damage resulting in failure.
    Support the flexible pipe with a support wrap or suitable splint.

  1. Detach the exhaust flexible pipe from the muffler and tailpipe assembly.
    • Discard the gasket and nuts.
  1. Lower the vehicle.

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

  1. Disconnect the headlamp wiring harness ground cable.

  1. Using the special tool and a engine hoist support the engine.

  1. Detach the engine front mount bracket from the side member.

  1. CAUTION:
    CAUTION:Make sure excessive force is not placed on the remaining engine mounts when moving the engine forward.
    Move the engine mount towards the front of the vehicle to its maximum deflection.
  1. Remove the brake booster.
    • Rotate the booster through 180 degrees, to aid removal.
    • Discard the gasket.

Installation
  1. CAUTION:
    CAUTION:Make sure that the brake booster actuating rod is correctly positioned through the bulkhead rubber boot.
    CAUTION:
    CAUTION:Make sure the brake booster gasket is correctly positioned on the brake booster before installation.
    NOTE:
    NOTE:Install a new brake booster gasket.
    NOTE:
    NOTE:Compress the brake booster actuating rod, to aid installation.
    Install the brake booster.

  1. NOTE:
    NOTE:Do not fully tighten at this stage.
    Install the brake booster retaining nuts

  1. Attach the engine front mount bracket to the side member.

  1. Connect the headlamp wiring harness ground cable.

  1. Attach the coolant expansion tank to the wheelhouse assembly.
    1. Position the tank.
    1. Install the bolt.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Install the engine support insulator centre bolt.

  1. NOTE:
    NOTE:Coat the flexible pipe studs with anti-seeze grease.
    NOTE:
    NOTE:Install a new exhaust gasket and nuts.
    Attach the exhaust flexible pipe to the muffler and tailpipe assembly.
    • Remove the support wrap or suitable splint.
  1. Lower the vehicle.
  1. Position the refrigerant lines into the engine compartment.

  1. Install the refrigerant line retaining bracket.

  1. Attach the refrigerant lines to the wheelhouse assembly.

  1. NOTE:
    NOTE:Install new O-rings on the refrigerant lines.
    NOTE:
    NOTE:Coat the O-rings for the refrigerant lines with clear refrigerant oil prior to installation.
    Install the refrigerant condenser line.

  1. NOTE:
    NOTE:Install new O-rings on the refrigerant lines.
    NOTE:
    NOTE:Coat the O-rings for the refrigerant lines with clear refrigerant oil prior to installation.
    Install the refrigerant line to the condenser at the evaporator.

  1. NOTE:
    NOTE:Install new O-rings on the refrigerant lines.
    NOTE:
    NOTE:Coat the O-rings for the refrigerant lines with clear refrigerant oil prior to installation.
    Install the refrigerant line to the accumulator at the evaporator.
  1. Charge the air conditioning. For additional information, refer to Section  412-00 Climate Control System - General Information.

  1. Install the right - hand front wheel fender splash shield.
  1. Install the right-hand front wheel and tire. For additional information, refer to Section  204-04 Wheels and Tires.

  1. Connect the A/C pressure switch electrical connector.

  1. Install the fuel lines.

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

  1. Attach the brake tubes to the bulk head.

  1. Attach the wiring harness to the bulk head.

  1. Tighten the brake pedal bracket nuts.

  1. CAUTION:
    CAUTION:Install a new actuating rod pin.
    Attach the brake booster actuating rod to the pedal.
    1. Depress the brake pedal.
    1. Install the brake booster actuating rod pin.

  1. Detach the instrument panel lower panel.
    1. Remove the screws.
    1. Release the fastener.

  1. Detach the data link connector and remove the instrument panel lower panel.

  1. Remove the air duct.
    1. Remove the fastener.
    1. Remove the air duct.

  1. Loosen the brake pedal retractor retaining bolt.

  1. CAUTION:
    CAUTION:Make sure there is clearance between the brake pedal and brake pedal retractor to allow free movement.
    Align the brake pedal retractor to the brake pedal bracket.

  1. Tighten the brake pedal bracket nuts.

  1. Tighten the brake pedal retractor arm retaining bolt.
  1. With the engine running depress the brake pedal three times to make sure the brake pedal moves freely and returns to the full brake off position.

  1. Install the air duct.
    1. Install the air duct.
    1. Secure the fastener.

  1. Attach the data link connector to the instrument panel lower panel.

  1. Install the instrument panel lower panel.
    1. Secure the fastener.
    1. Install the screw.

  1. NOTE:
    NOTE:The clutch position switch (colored red) is not adjustable.
    Pull out the speed control deactivation switch (if equipped) and stop lamp switch plungers until they are fully extended.
    • Measure the plunger length.
    • Speed control deactivation switch (colored green) XX mm = 24 mm.
    • Stop lamp switch (colored grey) XX mm = 21 mm.

  1. CAUTION:
    CAUTION:When installing the switches, the stop lamp switch is rotated counterclockwise and the remaining switches are rotated clockwise. Failure to follow this instruction will result in the switch plungers binding inside the switch.
    CAUTION:
    CAUTION:Make sure the switches are correctly installed.
    NOTE:
    NOTE:The speed control deactivation switch (if equipped) and the stop lamp switch are automatically adjusted during installation.
    NOTE:
    NOTE:A slight ratcheting noise and feel during installation of the speed control deactivation switch (if equipped) and the stop lamp switch is normal.
    Install the pedal position switches.
    1. Clutch position switch (colored red).
    1. Stop lamp switch (colored grey).
    1. Speed control deactivation switch (colored green) (if equipped).

  1. NOTE:
    NOTE:The colors of the electrical connectors and switches are identical.
    Connect the electrical connectors to the pedal switches.
    1. Speed control deactivation switch (if equipped).
    1. Stop lamp switch.
    1. Clutch position switch.
  1. Install the master cylinder. For additional information, refer to Section  206-06 Hydraulic Brake Actuation.

206-07 Power Brake Actuation|Specifications > < Brake Booster - 2.0L Duratec-RS (Zetec) LHD