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Assembly > < Engine - 1.6L Zetec-E (Zetec)

Focus 1999 (08.1998-12.2004)

Engine - 1.6L Zetec-E (Zetec)/1.8L Zetec-E (Zetec)/2.0L Zetec-E (Zetec) - Engine Focus 1999 (08/1998-12/2004)
Disassembly

Special Tool(s)

Slide hammer

205-047 (15-011)

Universal flange holding wrench

205-072 (15-030A)

Mounting bracket

303-435-04 (21-064)

Immobiliser, flywheel

303-254 (21-135)

Engine lifting tool

303-122 (21-068A)

Mounting plate

303-435-12 (21-150A)

Remover, oil pan

303-633 (21-227)

Pliers, spark plug connectors

303-622 (21-226)
General Equipment
Wooden blocks
Retaining straps
Workshop hoist

Disassembly

  1. General remarks.
    • The engine remains hooked on the workshop hoist until the assembly stand can be attached.
    • If the engine is positioned on the assembly table and needs to be temporarily unhooked from the workshop hoist, then it must be secured with retaining straps .
    • Cut cable ties as necessary and renew them during installation.

  1. Detach the catalytic converter bracket.

  1. Detach the catalytic converter.
    1. Detach the heat shield.
    1. Unscrew the bolt from the catalytic converter bracket.

  1. Detach the catalytic converter (cont.).

  1. Detach connector from oil pressure switch.

  1. Detach the generator.
    1. Disconnect the positive cable.
    1. Unscrew the bolt.
    1. Loosen the bolt.

  1. Detach the intake manifold.
    • Remove the seven bolts and unscrew two nuts.

  1. Detach the ancillary components on the intake side.
    1. Generator mounting bracket
    1. Oil filter
    1. Oil pressure switch

  1. Attach the engine to the assembly stand.
    1. Attach the special tool.
    1. Attach the special tool.

  1. Detach the ancillary components on the exhaust side.
    1. Bracket for power steering pump
    1. Bracket for air conditioning compressor

  1. Disconnect the positive crankcase ventilation.

  1. Detach the timing belt cover.
    1. Water pump belt pulley
    1. Drive belt idler pulley
    1. Center timing belt cover/front engine mounting bracket
    1. Upper timing belt cover
      NOTE:
      NOTE:Immobilize the flywheel using Special Tool 303-254.
    1. Detach the pulley/vibration damper from the crankshaft.
    1. Lower timing belt cover

  1. CAUTION:
    CAUTION:Do not pull the spark plug connectors by the cable when removing them. If necessary pull off the ignition leads from the ignition coils to prevent kinking the cables. Slightly twist the spark plug connectors before removing them in order to loosen the seals.
    CAUTION:
    CAUTION:Pull off each spark plug connector straight, in the direction the spark plug points (use Special Tool 303-622 for angled spark plug connectors).
    Detach the cylinder head cover.
    • Pull off the spark plug connectors.
    1. Unscrew the bolts.
    1. Unscrew the spark plugs.

  1. NOTE:
    NOTE:Design with lower idler pulley shown (built until about 01/99).
    NOTE:
    NOTE:Installation position of crankshaft timing belt pulley and thrust washer.
    Detach the timing belt drive and the water pump.
    1. Slacken the timing belt tensioner by twisting it counter-clockwise and detach it.
    1. Remove the timing belt.
    1. Detach the upper idler pulley.
    1. Detach the lower idler pulley.
    1. Detach the water pump.
    1. Detach the crankshaft timing pulley and the thrust washer.

  1. NOTE:
    NOTE:Design without lower idler pulley shown (built from about 01/99).
    NOTE:
    NOTE:Installation position of crankshaft timing belt pulley and thrust washer.
    Detach the timing belt drive and the water pump.
    1. Slacken the timing belt tensioner by twisting it counter-clockwise and detach it.
    1. Remove the timing belt.
    1. Remove idler pulley.
    1. Detach the water pump.
    1. Detach the crankshaft timing pulley and the thrust washer.

  1. Detach the camshaft timing pulleys.
    • Use the special tool to stop them from turning.

  1. NOTE:
    NOTE:Working in several stages, evenly loosen each bolt two turns at a time in the indicated sequence and remove the bolts.
    Detach the camshaft bearing caps.
    • Remove the oil seals.
    • Take out the camshafts.
    • Remove the valve tappets and lay them in order to one side.

  1. CAUTION:
    CAUTION:Center-punch the bolts once or twice to mark them for re-use. The bolts can be re-used twice. Discard the bolts as necessary.
    CAUTION:
    CAUTION:The cylinder head must cool down to room temperature before proceeding.
    NOTE:
    NOTE:Loosening sequence
    Unscrew and remove the cylinder head bolts.
  1. Lift off the cylinder head.

  1. Detach the clutch pressure plate and the clutch disc.

  1. Detach the flywheel.
    • Detach the special tool.

  1. Unscrew and remove the drain plug and the oil pan bolts.

  1. CAUTION:
    CAUTION:In order to prevent damage to the sealing surfaces, only use the designated special tool to remove the oil pan. Do not use a chisel or screwdriver for removal.
    Detach the oil pan.
    • Attach the special tool, tighten the lock nut against the oil pan and use several taps to release the oil pan from the lower crankcase.

  1. Detach the oil intake pipe and the lower crankcase.
    1. Oil intake pipe bolts
    1. Lower crankcase bolts

  1. Detach the oil pump.

  1. Detach the crankshaft rear oil seal carrier and the crankshaft position sensor (CKP sensor) together with its bracket.

  1. NOTE:
    NOTE:Lay all parts in order to side.
    Remove the crankshaft and pistons.
    1. Detach the big-end bearing caps.
    1. Detach the main bearing caps.
    1. Take out the crankshaft and press out the pistons with the connecting rods.

Assembly > < Engine - 1.6L Zetec-E (Zetec)