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Engine - Vehicles With: 4-Speed Automatic Transmission (4F27E) > < Assembly|Engine

Focus 1999 (08.1998-12.2004)

Engine - 1.4L/1.6L - Engine—Vehicles With: Manual Transaxle Focus 1999 (08/1998-12/2004)
Installation

Special Tool(s)

Lifting Bracket, Engine

303-122 (21-068A)

Remover/Installer, Hose Clamp

303-397 (24-003)
General Equipment
Auxiliary plug
Assembly stand
Tensioning strap
Jib crane

Installation

All vehicles
  1. General Notes
    • If necessary, use Special Tool 303-397 to install coolant and ventilation hoses.
    • The engine mounting positions are given looking from the transmission towards the engine.
  1. CAUTION:
    CAUTION:Ensure that the two guide sleeves are installed.
    Attach the engine to the transmission.

  1. Screw in the left-hand flange bolts.

  1. Screw in the right-hand flange bolts.
    • Attach the gearshift cable bracket.
  1. Place the engine and transmission assembly on the assembly stand.
    • Support the transmission with wooden blocks and secure with a tensioning strap.

  1. Remove the special tool.
  1. Raise the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).
  1. Locate the engine and transmission assembly with assembly stand in the installation position under the vehicle.
  1. Lower the vehicle and guide the engine and transmission assembly into the engine compartment.

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

  1. NOTE:
    NOTE:Do not fully tighten the front engine mount bolts and nuts at this stage.
    Attach the front engine mount.
  1. Remove the tensioning strap.
  1. Raise the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).
    • Pull the assembly stand out from under the engine and transmission assembly.

  1. Attach the clutch master cylinder pipe.

  1. CAUTION:
    CAUTION:The inner joint must not be bent more than 18 degrees, the outer one no more than 45 degrees.
    Install the left-hand front drive halfshaft in the transmission.
    • Remove the auxiliary plug from the transmission opening.

  1. NOTE:
    NOTE:Install a new intermediate shaft centre bearing cap and nuts.
    NOTE:
    NOTE:Insert the intermediate shaft into the transmission until the intermediate shaft bearing contacts the rib of the intermediate shaft bracket.
    Install the front drive halfshaft with intermediate shaft.
    • Remove the auxiliary plug from the transmission opening.

  1. Install the engine support insulator.

  1. Attach the vehicle speed sensor (VSS) connector.

  1. Attach the reversing lamp switch connector.
Vehicles with air conditioning
  1. Attach the power steering pump bracket with drive belt tensioner.
All vehicles
  1. Attach the lower suspension arm ball joint on both sides.

  1. Attach the gearshift and selector cables to the abutment and lock by turning the catch counter-clockwise.
    • Clip the gearshift cable to the gearshift lever.
    • Clip the selector cable to the selector lever.

  1. Attach the connector for the heated oxygen sensor (HO2S).

  1. Attach the connector for the crankshaft position sensor (CKP sensor).

  1. Attach the connector for the oil pressure switch.

  1. Attach the exhaust manifold to the front exhaust pipe.
    • Attach the exhaust manifold to the cylinder head.
    • Use new gaskets.
  1. Detach the flexible pipe support.

  1. Attach the starter motor ground cable.
Vehicles without air conditioning
  1. Attach the power steering pump with carrier plate.
    • Cut the cable ties.

  1. Attach the bracket of the power steering hydraulic line.
Vehicles with air conditioning
  1. Install the A/C compressor.

  1. Attach the bracket for the power steering high-pressure pipe.
All vehicles
  1. Install the auxiliary drive belt. For additional information, refer to: (303-05 Accessory Drive)
    Accessory Drive Belt (Removal and Installation),
    Accessory Drive Belt - Vehicles Built Up To: 03/2002, Vehicles Without: Accessory Drive Belt Tensioner (Removal and Installation),
    Accessory Drive Belt - Vehicles Built From: 03/2002, Vehicles Without: Accessory Drive Belt Tensioner (Removal and Installation).

  1. Attach the coolant hose.

  1. Attach the carbon canister vacuum line.

  1. Attach the coolant and heating hoses.
    1. Reservoir coolant hose.
    1. Heater hose.
    1. Coolant hose.
Vehicles without air conditioning
  1. Attach the connector and cable.
    1. Connect the generator.
    1. Attach the power steering pump connector.
Vehicles with air conditioning
  1. Connect the generator.
All vehicles
  1. Tighten the rear engine mount.

  1. Tighten the front engine mount.

  1. Connect the heater hose.

  1. Attach the vacuum hoses.
    1. Fuel pressure regulator vacuum hose.
    1. Brake servo vacuum hose.

  1. Attach the engine wiring harness connector
    • Clip in the gearshift cables.

  1. Attach connectors.
    1. Ignition coil (EI).
    1. Condenser.

  1. NOTE:
    NOTE:Use a new exhaust manifold gasket.
    Attach the exhaust manifold (shown from below).

  1. Attach the exhaust manifold heat shield and engine ground cable.
    1. Exhaust manifold heat shield.
    1. Engine ground cable.

  1. Connect the fuel lines.

  1. Attach the engine wiring harness multiplug and the connector for the camshaft position (CMP) sensor.

  1. Attach the accelerator cable.
    1. Attach the clip.
    1. Screw the cable into the bracket.

  1. Install the intake pipe.

  1. Install the air cleaner with the intake hose.
    1. Intake hose.
    1. Attach the mass air flow (MAF) sensor multiplug.
    • Attach the crankcase ventilation hose to the cylinder head.

  1. Clip on the power steering reservoir.

  1. Tighten the right and left-hand suspension strut nuts.

  1. Install the battery tray.
    1. Clip the wiring harness in place.
    1. Tighten the bolts.
    1. Clip on and attach the connector.
  1. Install a new oil filter.
  1. Fill up with engine oil.
    For additional information, refer to: Specifications (303-01A Engine - 1.4L/1.6L, Specifications).
  1. Fill up with coolant.
    For additional information, refer to: Cooling System Draining, Filling and Bleeding (303-03 Engine Cooling, General Procedures).
  1. Bleed the clutch hydraulic system.
    For additional information, refer to: Clutch System Bleeding - Vehicles With: 5-Speed Manual Transmission (iB5) (308-00 Manual Transmission/Transaxle and Clutch - General Information, General Procedures).
  1. Install the battery.
    For additional information, refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
Vehicles with front and rear power windows
  1. Initialize the window winder motors.
    For additional information, refer to: Door Window Motor Initialization (501-11 Glass, Frames and Mechanisms, General Procedures).

Engine - Vehicles With: 4-Speed Automatic Transmission (4F27E) > < Assembly|Engine