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Engine - Vehicles With: 5-Speed Manual Transmission (MTX-75) > < Assembly|Engine

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 (iB5) Focus 1999 (08/1998-12/2004)
Installation

Special Tool(s)

Lifting Tackle, Engine

303-122 (21-068A)

Aligner, Gearshift Lever

308-273 (16-088)

Remover and Installer, Radiator Hose Clip

303-397 (24-003)
General Equipment
Assembly stand
Tensioning strap
Jib crane
Wooden blocks
Materials
Name
Specification
Cable ties
 
High-temperature grease
ESD-M1C220-A 

Installation

All vehicles
WARNING:
WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to observe this instruction can lead to injury.
  1. General Note.
    • If necessary, use Special Tool 303-397 to install coolant and ventilation hoses.

  1. Preparations.
    • Hook the engine into the jib crane , bring into position at the transmission and support using wooden blocks.

  1. Tighten the flange bolts.

  1. Tighten the flange bolts (Cont'd).

  1. Install the starter motor and tighten the flange bolt.
    1. Starter motor bolt
    1. Flange bolt
  1. Raise the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Position the engine and transmission assembly on the assembly stand below the vehicle.
    • Carefully lower the vehicle.

  1. NOTE:
    NOTE:Insert/screw on the bolts and nuts finger tight.
    Install the front engine mounting.

  1. NOTE:
    NOTE:Screw on the nuts finger tight.
    Install the rear engine mounting.

  1. CAUTION:
    CAUTION:Brake fluid will escape. Observe the safety regulations for working with brake fluid. For additional information, refer to Section  206-00 Brake System - General Information.
    Attach the pressure pipe to the clutch slave cylinder.
  1. Remove the retaining strap from the transmission.
  1. Raise the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.
    • Remove the assembly stand.

  1. Install the engine roll restrictor.

  1. CAUTION:
    CAUTION:The inner joint must not be bent more than 18 degrees, the outer one no more than 45 degrees.
    NOTE:
    NOTE:Use new bolts and new center bearing caps.
    Install the right-hand front halfshaft with the intermediate shaft.

  1. NOTE:
    NOTE:Engage the snap-ring properly.
    Install left-hand front halfshaft in transmission together with new retaining ring.

  1. Attach both suspension arms (right-hand side shown).
  1. Attach both front wheels. For additional information, refer to Section  204-04 Wheels and Tires.

  1. Install the flexible exhaust pipe.
  1. Lower the vehicle.

  1. Tighten the rear engine mounting nuts/bolts.

  1. Tighten the front engine mounting nuts.

  1. Install the power steering pump and install the upper bolts.

  1. Attach the bracket to the power steering high-pressure pipe.

  1. Insert the power steering fluid reservoir.

  1. Install the coolant expansion tank.
  1. Raise the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Screw in the two lower bolts of the power steering pump and attach the coolant hose.
Vehicles with air conditioning
  1. Install the air conditioning compressor.
All vehicles
  1. Fit and tension the drive belt. (Vehicle without air conditioning shown)
    • Rotate the tensioner clockwise.

  1. Install the drive belt cover.

  1. Attach the gearshift and selector cables.
    • Attach the gearshift and selector cables to the bracket by twisting the abutment collar clockwise.

  1. Top up with transmission fluid until the fluid level is 10 to 15 mm below the lower edge of the check hole.

  1. Close the cover for the gearshift and selector cables.

  1. Install the air deflector and the radiator fan.
    • Position the air deflector and clip on at the top on both sides (left-hand side shown).
  1. Lower the vehicle.

  1. Attach the coolant hoses.
Vehicles with LPG fuel system
  1. Disconnect the gas hose from the gas manifold.
All vehicles
  1. Connect the fuel pipes.
    • Attach the ground lead.

  1. Connect the brake servo vacuum hose.

  1. Connect the vacuum hoses.

  1. Attach the connector for the reversing lamp switch and the CKP.
    • Clip the wiring harness to the engine.

  1. Attach the VSS connector.

  1. Attach the engine wiring harness connector.

  1. CAUTION:
    CAUTION:Brake fluid will escape. Observe the safety regulations for working with brake fluid. For additional information, refer to Section  206-00 Brake System - General Information.
    Connect the pressure pipe to the clutch slave cylinder.
    • Push on the spring clip.

  1. Attach the radiator fan connector.
    • Attach the cable tie.

  1. Attach the PCM connector.

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

  1. Attach the connectors of the EI coil and the radio interference filter.

  1. Attach the accelerator cable.
    1. Hook the cable in place.
    1. Attach the plastic clip.

  1. Install the intake pipe.

  1. Attach the ground lead.

  1. Install the air cleaner housing.
    • Insert the air cleaner housing into the rubber bushings.
    1. Attach the MAF connector.
    1. Install the crankcase ventilation hose.
    1. Attach the intake hose.

  1. NOTE:
    NOTE:Stop it from turning using an Allen key.
    Tighten the suspension strut nut on the right and left-hand side.
    • Tighten by hand with a ring spanner.
    • Use a torque wrench to tighten to torque.

  1. Install the battery tray.
    1. Attach the positive and ground leads.
    1. Install the bolts.
    1. Clip the wiring harness in place.
    1. Fasten the connector and clip it in.
  1. Install the battery.

  1. Remove the special tool.
    • Clip on the bellows and boot.

  1. Tighten the wheel nuts.
  1. Standard finishing operations.
    • Enter the radio keycode.
    • Reprogram the preset radio stations.
    • Carry out a road test to enable the PCM to collect data.
Vehicles with front and rear power windows
  1. Initialize the window winder motors. For additional information, refer to Section  501-11 Glass, Frames and Mechanisms.

Engine - Vehicles With: 5-Speed Manual Transmission (MTX-75) > < Assembly|Engine