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Ford Workshop Service and Repair Manuals

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Engine - 1.6L Zetec-E (Zetec) > < Engine - Vehicles With: 5-Speed Manual Transmission (MTX-75)

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: 4-Speed Automatic Transmission (4F27E) Focus 1999 (08/1998-12/2004)
Installation

Special Tool(s)

Lifting Bracket, Engine

303-122 (21-068A)

Remover/Installer, Cooling Hose Clamp

303-397 (24-003)
General Equipment
Jib crane
Workshop jack

Installation

All vehicles
  1. Check the torque converter installation depth.
    1. Lay a straight edge on the automatic transmission flange.
    1. Measure the installation depth between the automatic transmission flange and the torque converter and adjust if necessary.
  1. Apply high temperature grease thinly to the torque converter centering spigot.
  1. Carefully guide the engine into the engine compartment.
  1. Attach the engine to the transmission.

  1. Install the transmission flange upper bolts.

  1. Attach the front engine mounting.

  1. Remove the special tool.
  1. Raise the vehicle. For additional information, refer to: (100-02 Jacking and Lifting)
    Jacking (Description and Operation),
    Lifting (Description and Operation).

  1. Install the transmission flange lower bolts.

  1. Install the transmission flange lower bolts.

  1. Attach the torque converter to the drive plate.
  1. Lower the vehicle.

  1. Attach the selector cable to the transmission.

  1. Connect the fuel lines. For additional information, refer to:
    Fuel System Pressure Release (310-00A Fuel System - General Information, General Procedures),
    Quick Release Coupling (310-00A Fuel System - General Information, General Procedures),
    Spring Lock Couplings (310-00A Fuel System - General Information, General Procedures),
    Federclipkupplungen (310-00A Kraftstoffsystem - Allgemeine Informationen, General Procedures).

  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. Raise the vehicle. For additional information, refer to: (100-02 Jacking and Lifting)
    Jacking (Description and Operation),
    Lifting (Description and Operation).

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

  1. Attach the connector for the heated oxygen sensor (HO2S).
Vehicles with air conditioning
  1. Install the bracket and power steering pump with drive belt tensioner.

  1. Attach the bracket for the power steering high-pressure pipe.
All vehicles
  1. Attach the engine support insulator.

  1. NOTE:
    NOTE:Renew the retaining clip and nuts on the intermediate bearing.
    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.

  1. Attach the right-hand lower suspension arm ball joint.
Vehicles with air conditioning
  1. Attach the A/C compressor (four bolts).
    • Cut the cable ties.
Vehicles without air conditioning
  1. Attach the power steering pump with carrier plate.
    • Cut the cable ties.
All vehicles
  1. Attach the oil cooler lines to the oil cooler.

  1. Attach the starter motor ground cable.
  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. Position the automatic transmission fluid dipstick tube and screw in the bolt.

  1. Connect the vacuum lines to the EVAP canister solenoid valve.

  1. Attach the engine wiring harness connector.

  1. Connect the generator.
    • Positive lead.
    • Attach the connector.

  1. Clip in the power steering reservoir.

  1. Attach the coolant reservoir coolant hose.

  1. Attach the coolant hose.

  1. Connect the heater coolant hose.

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

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

  1. Attach the bracket of the power steering hydraulic line.

  1. Attach the carbon canister vacuum line.

  1. Attach the coolant and heating hoses.
    1. Expansion tank coolant hose.
    1. Heater hose.
    1. Coolant hose.

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

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

  1. Tighten the right-hand suspension strut nuts.

  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. Install the battery tray.
    1. Clip on and attach the connector.
    1. Tighten the bolts.
    1. Clip the wiring harness in place.
    • Install the battery.
      For additional information, refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).

  1. Install the air cleaner with the intake hose.
    1. Intake hose.
    1. Connect the mass air flow (MAF) sensor multiplug.
    1. Attach the crankcase ventilation hose to the cylinder head.
  1. If necessary install a new oil filter and top up with engine oil to specification.
  1. Standard finishing operations.
    • Fill up with coolant.
      For additional information, refer to: Cooling System Draining, Filling and Bleeding (303-03 Engine Cooling, General Procedures).
    • Check the engine oil level.
    • Check fluid levels again and correct if necessary.
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 - 1.6L Zetec-E (Zetec) > < Engine - Vehicles With: 5-Speed Manual Transmission (MTX-75)