ford Workshop Repair Guides

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)
Installation

Special Tool(s)

Aligner. Gearshift Lever - Neutral Position

307-350 (16-088)

Lifting Bracket, Engine

303-122 (21-068A)

Remover/Installer, Cooling Hose Clamp

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 
Transmission fluid
ESD-M2C186-A 

Installation

All vehicles
  1. General Note.
    • If necessary, use Special Tool 303-397 to install coolant and ventilation hoses.

  1. Preparatory measures:
    • Suspend the engine from the jib crane, bring into position at the transmission and support using wooden blocks.

  1. Screw in the flange bolts.

  1. Screw in the flange bolts.
    • Detach the jib crane from the engine.

  1. Install the starter motor and ground lead.
  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 only finger tight.
    Install the front engine mounting.

  1. NOTE:
    NOTE:Screw on the nuts finger tight.
    Install the rear engine mounting.
  1. Remove the tensioning 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 support insulator.

  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 cover.
    Attach the right-hand front drive halfshaft together with the intermediate shaft.

  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 a new snap-ring.
    NOTE:
    NOTE:Snap ring engages.
    Attach the left-hand front drive halfshaft.

  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 front engine mounting nuts/bolts.

  1. NOTE:
    NOTE:Tightening sequence
    Install the rear engine mounting nuts free of stress.
    • First tighten the M14 nut.
    • Then tighten the M10 nuts evenly, working diagonally.

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

  1. Attach the power steering pressure pipe bracket.

  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 A/C 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. Install the air deflector and the radiator fan.
    • Set the air deflector in the installation position and clip on at the top on both sides (left-hand side shown).
  1. Lower the vehicle.

  1. Attach the coolant hoses.

  1. NOTE:
    NOTE:The adjusting mechanism must be unlocked.
    Attach the gearshift and selector cables to the transmission and adjust.
    1. Loosen the abutment collar by turning it counter-clockwise and insert the selector cable into the bracket.
    1. Attach the gearshift cable to the gear selector lever.
    1. Loosen the abutment collar by turning it counter-clockwise and insert the gearshift cable into the bracket.
    1. Attach the gearshift cable to the gearshift lever.
    1. Lock the adjusting mechanism by pressing in the tab.

  1. Attach 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 in place.

  1. Attach the engine wiring harness connector.

  1. Attach the VSS 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 high-pressure pipe to the clutch slave cylinder.
    • Push on the spring clip.

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

  1. Attach the radiator fan connector.
    • Fit the cable ties.

  1. Attach the PCM connector.

  1. Attach the generator connector.

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

  1. Attach the accelerator cable.
    1. Attach the cable.
    1. Attach the plastic clip.

  1. NOTE:
    NOTE:The resonator is a push-fit.
    Install the air cleaner intake with resonator.

  1. Install the intake tube.

  1. Attach the ground lead.

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

  1. NOTE:
    NOTE:Counterhold 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 place.
  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.
    • Store 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: 4-Speed Automatic Transmission (4F27E) > < Engine - Vehicles With: 5-Speed Manual Transmission (iB5)