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303-01G Engine - 2.0L Duratec-ST (Zetec)|Specifications > < Assembly|Engine

Focus 1999 (08.1998-12.2004)

Engine - 2.0L Duratec-ST (Zetec) - Engine Focus 1999 (08/1998-12/2004)
Installation

Special Tool(s)

Lifting Bracket, Engine

303-122 (21-068A)

Remover/Installer, Hose Clamp

303-397 (24-003)
General Equipment
Securing strap
Assembly table
Materials
Name
Specification
Engine oil
WSS-M2C912-A1 
All vehicles
  1. Install the transaxle.

  1. Install the transaxle left-hand retaining bolts.

  1. Install the transaxle right-hand retaining bolts.

  1. Attach the starter motor to the transaxle.

  1. Install the starter motor upper retaining bolts.
    • Attach the ground cable to the transaxle.

  1. Install the transaxle upper retaining bolts.

  1. Using a securing strap, secure the transmission on the assembly table.
    • Remove the special tools.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Position the engine and transmission assembly under the vehicle.
    • Carefully lower the vehicle.

  1. NOTE:
    NOTE:Do not tighten the engine front mount bolts and nuts at this stage.
    Install the engine front mount.

  1. NOTE:
    NOTE:Do not tighten the engine rear mount bolts at this stage.
    Install the engine rear mount.
  1. Remove the securing strapfrom the engine and transmission assembly, and remove the assembly table.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Connect the reversing lamp switch electrical connector.
    • Clip on the wiring loom.

  1. Connect the vehicle speed sensor (VSS) electrical connector.
  1. Install the cooling fan motor and shroud. For additional information, refer to Section  303-03 Engine Cooling.

  1. NOTE:
    NOTE:Install a new exhaust flange gasket and new nuts.
    Attach the catalytic converter to the exhaust manifold.

  1. Install the catalytic converter bracket.

  1. Install the heated oxygen (HO2S) sensor.

  1. Connect the HO2S sensor electrical connector.

  1. Install the catalyst monitor sensor.

  1. Connect the catalyst monitor sensor electrical connector.

  1. Connect the crankshaft position (CKP) sensor electrical connector.

  1. Install the flexible exhaust pipe.

  1. CAUTION:
    CAUTION:Support the halfshaft. The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.
    Attach the right-hand halfshaft to the intermediate shaft.

  1. CAUTION:
    CAUTION:Support the halfshaft. The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.
    CAUTION:
    CAUTION:Do not damage the halfshaft oil seal.
    CAUTION:
    CAUTION:Make sure the snap ring is correctly seated.
    NOTE:
    NOTE:Install a new snap ring.
    Attach the left-hand halfshaft to the transaxle.

  1. Attach the lower arm to the wheel knuckle on both sides.

  1. Install the engine roll restrictor.

  1. Attach the power steering pump to the retaining bracket.

  1. Using the special tool, connect the coolant hose to the water pump.

  1. Connect the coolant hose to the oil cooler.
Vehicles with air conditioning
  1. Attach the air conditioning compressor.
All Vehicles
  1. Install the accessory drive belt. For additional information, refer to Section  303-05 Accessory Drive.

  1. Attach the gearshift cables to the transaxle.
    1. Attach the retaining bracket to the transaxle.
    1. Attach the gearshift cable and the selector cable to the selector levers.
  1. Lower the vehicle.

  1. Tighten the engine front mount nuts and bolts.

  1. Tighten the engine rear mount nuts.

  1. Install the coolant expansion tank.

  1. Install the power steering pump upper retaining bolts.

  1. Attach the power steering high pressure pipe to the cylinder head.

  1. Using the special tool, connect the coolant hoses to the thermostat housing.

  1. Attach the fuel line to the fuel rail.

  1. Attach the brake booster pipe to the intake manifold.

  1. Attach the vacuum hoses to the throttle body.

  1. Connect the wiring harness electrical connectors.

  1. Connect the ignition coil electrical connector.

  1. WARNING:
    WARNING:Escaping brake fluid. Do not allow brake fluid to come into contact with the skin or eyes. If brake fluid should come into contact with your skin or eyes, rinse the affected area immediately with water.
    CAUTION:
    CAUTION:If any brake fluid gets on the paintwork wash it off immediately with water.
    Attach the clutch supply line to the clutch slave cylinder.
    • Install the clip.

  1. Connect the generator electrical connector.

  1. Connect the fuel injector wiring harness electrical connectors.

  1. Connect the ground cable to the engine lifting eye.

  1. Attach the accelerator cable and the speed control cable (if equipped) to the throttle body.

  1. Install the air cleaner intake tube and resonator.

  1. Tighten the strut and spring assembly top mount retaining nuts on both sides.

  1. Attach the ground cable to the inner fender.
  1. Adjust the gearshift cables. For additional information, refer to Section  308-00 Manual Transmission/Transaxle and Clutch - General Information.
  1. Install the air cleaner. For additional information, refer to Section  303-12 Intake Air Distribution and Filtering.
  1. Install the battery tray. For additional information, refer to Section  414-01 Battery, Mounting and Cables.
  1. Connect the battery ground cable. For additional information, refer to Section  414-01 Battery, Mounting and Cables.
  1. Fill the cooling system. For additional information, refer to Section  303-03 Engine Cooling.
  1. Fill the transaxle with manual transmission fluid. For additional information, refer to Section  308-00 Manual Transmission/Transaxle and Clutch - General Information.
  1. Fill the engine with engine oil.
  1. Bleed the hydraulic clutch operating system. For additional information, refer to Section  308-00 Manual Transmission/Transaxle and Clutch - General Information.
  1. Fill and bleed the power steering. For additional information, refer to Section  211-00 Steering System - General Information.
Vehicles with front and rear power windows
  1. Initialize the door window motors. For additional information, refer to Section  501-11 Glass, Frames and Mechanisms.

303-01G Engine - 2.0L Duratec-ST (Zetec)|Specifications > < Assembly|Engine