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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)
Removal

Special Tool(s)

Lifting bracket, engine

303-122 (21-068A)
General Equipment
Workshop hoist
Trolley jack

Removal

All vehicles
  1. Release the pressure in the fuel system.
    For additional information, refer to: Druck - Kraftstoffsystem ablassen (310-00A, General Procedures).
  1. WARNING:
    WARNING:Danger of scalding if the engine is warm.
    Open the coolant expansion tank.
  1. Drain off the coolant.
    For additional information, refer to: Kühlsystem entleeren, mit Kühlmittel auffüllen und entlüften (303-03, General Procedures).

  1. Remove the air cleaner with air intake hose.
    1. Air intake hose
    1. Disconnect the mass air flow sensor (MAF sensor) connector.
    1. Detach the PCV hose from the cylinder head cover.
  1. Remove battery.
    For additional information, refer to: Batterie (414-01, Removal and Installation).

  1. Remove the battery tray.
    1. Unclip and separate the connector.
    1. Unscrew the bolts.
    1. Unclip the wiring harness.

  1. Undo the right-hand suspension strut nut three turns.

  1. Remove the air cleaner with air intake hose.
    1. Air intake hose
    1. Disconnect the mass air flow sensor (MAF sensor) connector.
    • Detach the PCV hose from the cylinder head cover.

  1. Remove the intake pipe.

  1. Detach the accelerator cable.
    1. Pull off the clip.
    1. Unscrew the cable from the bracket.

  1. Disconnect the plug.
    1. Ignition coil (EI)
    1. Condenser

  1. Detach the coolant and heating hoses.
    1. Reservoir coolant hose
    1. Heater coolant hose
    1. Radiator coolant hose

  1. Detach the carbon canister vacuum line.

  1. Pull off the hoses and disconnect the plug.
    1. Vacuum hose - fuel pressure control
    1. Brake servo vacuum hose.

  1. Disconnect the plug for the crankshaft position sensor (CKP sensor).

  1. Separate the heater coolant hose.

  1. Detach the coolant hose.

  1. Detach the coolant reservoir coolant hose.

  1. Unclip the power steering reservoir and lay it to one side.

  1. Disconnect the generator.
    • Disconnect the positive cable.
    • Disconnect the plug.

  1. Separate the engine wiring harness connector.

  1. Separate the vacuum lines of the EVAP canister solenoid valve.

  1. Unscrew the bolt of the automatic transmission dipstick tube and turn the tube to one side.
  1. Remove the auxiliary drive belt. For additional information, refer to: (303-05 )
    Antriebsriemen - Zusatzaggregate (Removal and Installation),
    Antriebsriemen - Zusatzaggregate - gebaut bis 03/2002, Fahrzeuge nicht ausgestattet mit Riemenspanner-Nebenaggregate (Removal and Installation),
    Antriebsriemen - Zusatzaggregate - gebaut ab 03/2002, Fahrzeuge nicht ausgestattet mit Riemenspanner-Nebenaggregate (Removal and Installation).

  1. Disconnect the starter motor ground cable.

  1. Disconnect the oil cooler lines from the oil cooler.
Vehicles without air conditioning
  1. Detach the bracket of the power hydraulic line.

  1. Detach the power steering pump with carrier plate.
    • Tie up using cable ties.
Vehicles with air conditioning
  1. Detach the air conditioning compressor (four bolts)
    • Tie up with cable ties.
All vehicles
  1. Detach the lower suspension arm on the right-hand side.

  1. Detach the retaining clip from the right-hand front axle halfshaft centre bearing.
    • Discard the retaining clip and nuts

  1. Detach the bracket for the centre bearing of the right-hand front axle halfshaft (four bolts).

  1. CAUTION:
    CAUTION:The inner joint must not be bent at more than 18°; the outer joint must not be bent at more than 45°.
    Remove the right-hand front axle halfshaft from the transmission and tie up.
    • Close off the transmission with auxiliary plugs.

  1. NOTE:
    NOTE:The roll restrictor is under stress.
    Remove the engine roll restrictor.

  1. Disconnect the heated oxygen sensor (HO2S) multiplug.

  1. Detach the bracket of the power steering high-pressure pipe.
Vehicles fitted with air conditioning
  1. Detach the bracket and power steering pump with drive belt tensioner.
    • Tie up with cable ties.
All vehicles
  1. CAUTION:
    CAUTION:If the flexible pipe is bent too sharply, damage may be caused which can lead to failure of the component.
    Protect the flexible pipe with a support sleeve or suitable splints.

  1. Unfasten the front exhaust pipe flange.
    • Remove the gasket.
  1. Lower the vehicle.

  1. Detach the engine ground cable and exhaust manifold heat shield.
    1. Engine ground cable
    1. Exhaust heat shield (three bolts).

  1. Detach the exhaust manifold (shown from below).
    • Lean the exhaust manifold against the bulkhead and secure it as necessary.

  1. Detach the torque converter from the drive plate (four bolts).
    • Use a suitable tool to separate the torque converter from the drive plate.

  1. Remove the transmission lower flange bolts.

  1. Remove the transmission lower flange bolts.
  1. Lower the vehicle.

  1. Detach the selector cable from the transmission.

  1. Disconnect the fuel lines. For additional information, refer to: (310-00A )
    Schnellkupplung (General Procedures),
    Federclipkupplungen (General Procedures).

  1. Hook the engine into the workshop hoist using the special tool.

  1. Detach the front engine mounting.
    • Remove the front engine mounting bracket.
  1. WARNING:
    WARNING:Do not support under the automatic transmission oil pan.
    CAUTION:
    CAUTION:The inner joint must not be bent at more than 18°; the outer joint must not be bent at more than 45°.
    Support the transmission on wood on a workshop jack.

  1. Remove the transmission flange upper bolts.
  1. WARNING:
    WARNING:The torque converter can fall out of the automatic transmission.
    Detach the engine from the transmission.
  1. NOTE:
    NOTE:Torque converter.
    Remove the engine.
  1. Secure the torque converter to stop it falling out, or if necessary remove it.

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