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Engine - Vehicles With: 5-Speed Manual Transmission (MTX-75) > < In-vehicle Repair|Oil Pan

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)
Removal

Special Tool(s)

Lifting Tackle, Engine

303-122 (21-068A)

Remover, Halfshaft

308-237 (16-087)

Remover and Installer, Radiator Hose Clip

303-397 (24-003)
General Equipment
Auxiliary plugs
Assembly stand
Tensioning strap
Jib crane
Wooden blocks
Materials
Name
Specification
Cable ties
 

Removal

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 Notes.
    • The position markings for the engine mountings and engine roll restrictors are described looking from the transmission towards the engine.
    • If necessary, use Special Tool 303-397 to remove coolant and ventilation hoses.
    • Any steps which only apply to certain variants and not to all vehicles are clearly indicated.
    • If necessary, unfasten cable ties and fit new ones when reinstalling.
  1. Standard preparatory measures
    • Make a note of the radio keycode.
    • Make a note of the pre-set radio stations.
  1. Drain the coolant. For additional information, refer to Section  303-03 Engine Cooling.

  1. CAUTION:
    CAUTION:Disconnect the battery positive and ground leads. Remove the battery.
    Remove the battery tray and detach the ground lead.
    1. Unclip and separate the connector.
    1. Unclip the wiring harness.
    1. Remove the bolts.
    1. Detach the positive and ground leads.

  1. Remove the air cleaner housing.
    1. Detach the mass air flow sensor (MAF) connector.
    1. Detach the crankcase ventilation hose.
    1. Disconnect the intake hose.
    • Pull out the air cleaner housing from the rubber bushes.

  1. Detach the ground lead.

  1. Remove the intake pipe.

  1. NOTE:
    NOTE:Stop it from turning using an Allen key.
    Undo the nuts on both suspension struts five turns.

  1. Loosen the wheel nuts of the left and right-hand front wheels.

  1. Lock the gearshift lever using the special tool.
    • Shift the gearshift mechanism to neutral.
    • Remove the gearshift lever cover and insert special tool.

  1. Detach the accelerator cable.
    1. Disconnect the cable.
    1. Pull off the plastic clip and lay the accelerator cable to one side.

  1. Detach the EI coil and the radio interference filter connectors.

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

  1. Detach the radiator fan connector.
    • Cut the cable ties.

  1. Detach the powertrain control module (PCM) connector.

  1. Detach the generator 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.
    Detach the pressure pipe from the clutch slave cylinder.
    • Pull out the clip.
    • Pull out the pressure pipe and tie it up with cable ties.

  1. Detach the engine wiring harness connector.

  1. Detach the vehicle speed sensor (VSS) connector.

  1. Detach the reversing lamp switch and crankshaft position sensor (CKP)connectors.
    • Unclip the wiring harness from the engine.

  1. Remove the air deflector and the radiator fan.
    • Undo the clips on both sides (left side shown).
    • Detach the air deflector upwards and remove it downwards.

  1. Disconnect the vacuum hoses.

  1. Disconnect the brake servo vacuum hose.

  1. Detach the quick-release couplings for the fuel supply line and fuel return line. For additional information, refer to Section  310-00A Fuel System - General Information / 310-00B Fuel System - General Information / 310-00C Fuel System - General Information.
    • Detach the ground lead.
Vehicles with LPG fuel system
  1. Disconnect the gas hose from the gas manifold.
All vehicles
  1. Detach the coolant hoses.
  1. Raise the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Detach the shift cable and the selector cable.
    • Detach the shift and selector cables by twisting the abutment collar clockwise.

  1. Remove the drive belt cover.

  1. Slacken the drive belt and remove it (vehicle without air conditioning shown).
    • Rotate the tensioner clockwise.
Vehicles with air conditioning
  1. Detach the air conditioning compressor and tie it up on the radiator crossmember.
All vehicles
  1. Remove the bolts of the power steering pump and detach the coolant hose.
  1. Lower the vehicle.

  1. Detach the coolant expansion tank and place it to one side.

  1. Remove the power steering fluid container and place to one side.

  1. Remove power steering pressure pipe bracket.

  1. Detach the power steering pump and tie it up with cable ties.
  1. Raise the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Remove the flexible exhaust pipe.

  1. Remove the engine roll restrictor.

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

  1. CAUTION:
    CAUTION:The inner joint must not be bent more than 18 degrees, the outer one no more than 45 degrees.
    Detach the right-hand front halfshaft together with the intermediate shaft.
    • Remove the intermediate shaft bearing cap.
    • Discard the nuts and bearing cap.
    • Pull out the intermediate shaft from the transmission together with the front halfshaft and tie up using cable ties.

  1. CAUTION:
    CAUTION:The inner joint must not be bent more than 18 degrees, the outer one no more than 45 degrees.
    Detach the left-hand front halfshaft from the transmission and tie it up.
  1. Position the assembly stand with wooden blocks fitted under the vehicle .
  1. Carefully lower the vehicle until the engine and transmission assembly is on the assembly stand.

  1. Secure the engine and transmission assembly on the assembly stand with a retaining strap.

  1. Remove the rear engine mounting.

  1. Remove the front engine mounting.
  1. Carefully raise the vehicle.
    • Pull out the assembly stand with the engine-transmission assembly.

  1. Hook the engine and transmission assembly into the jib crane.

  1. Unscrew the upper bolts.
    1. Flange bolts
    1. Starter motor bolt
    • Detach the ground lead.

  1. Remove flange bolt and push starter motor to one side.
    1. Starter motor bolt
    1. Flange bolt

  1. Remove the lower flange bolts.

  1. Remove the flange bolts.

Engine - Vehicles With: 5-Speed Manual Transmission (MTX-75) > < In-vehicle Repair|Oil Pan