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Disassembly and Assembly of Subassemblies > < In-vehicle Repair|Engine

Focus 1999 (08.1998-12.2004)

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

Special Tool(s)

Slide Hammer

205-047 (15-011)

Mounting Bracket for 303-435

303-435-04 (21-064)

Locking Tool, Flywheel

303-254 (21-135)

Lifting Bracket, Engine

303-122 (21-068A)

Mounting Plate for 303-435-04

303-435-12 (21-150A)

Adapter for 205-047

303-633 (21-227)

Socket, Cylinder Head Bolt

303-392 (21-167)
General Equipment
Assembly stand
  1. Disconnect the oil pressure switch and the knock sensor (KS) electrical connectors.

  1. Remove the generator.
    1. Disconnect the positive cable.
    1. Remove the bolt.
    1. Remove the bolt.

  1. Remove the ancillary components on the intake side.
    1. Generator mounting bracket.
    1. Oil filter.
    1. Knock sensor (KS).
    1. Oil pressure switch.

  1. Remove the oil cooler.

  1. Install the mounting plate to the engine.

  1. Install the mounting bracket to the mounting plate.
  1. Attach the engine to the assembly stand and remove the engine lifting bracket.

  1. Remove the ancillary components on the exhaust side.
    1. Power steering pump bracket.
    1. Air conditioning compressor bracket.

  1. Disconnect the positive crankcase ventilation.
  1. Remove the clutch assembly. For additional information, refer to Section  308-01A Clutch / 308-01B Clutch / 308-01D Clutch.

  1. Using the special tool, lock the flywheel in position.

  1. Remove the timing belt cover.
    1. Water pump belt pulley.
    1. Drive belt idler pulley.
    1. Engine front mount bracket.
    1. Upper timing belt cover.
    1. Remove the damper from the crankshaft pulley.
    1. Lower timing belt cover.

  1. CAUTION:
    CAUTION:Do not pull the spark plug electrical connectors by the ignition cables when removing them. If necessary disconnect the ignition cables from the ignition coils to prevent damage to the cables. Slightly twist the spark plug electrical connectors before removing them to loosen the seals.
    CAUTION:
    CAUTION:Pull off the spark plug electrical connectors in line with the spark plugs.
    Disconnect the spark plug electrical connectors.

  1. Remove the valve cover.

  1. NOTE:
    NOTE:Installation position of crankshaft timing belt pulley and thrust washer.
    Remove the timing belt drive and the water pump.
    1. Slacken the timing belt tensioner by twisting it counter-clockwise and remove it.
    1. Remove the timing belt.
    1. Remove the idler pulley.
    1. Remove the water pump.
    1. Remove the crankshaft timing pulley and the thrust washer.

  1. NOTE:
    NOTE:Hold the camshaft by the hexagon with an open ended wrench to prevent it from rotating.
    Remove the intake camshaft pulley blanking plug.

  1. NOTE:
    NOTE:Hold the camshafts by the hexagon with an open ended wrench to prevent them from rotating.
    Remove the camshaft pulleys.

  1. Remove the oil feed flange.
    • Discard the camshaft oil seals.
    • Discard the oil feed flange oil seal.

  1. CAUTION:
    CAUTION:Loosen and remove the camshaft bearing cap retaining bolts in the sequence shown.
    NOTE:
    NOTE:Working in several stages, evenly loosen each bolt two turns at a time in the sequence shown.
    Remove the camshafts.
    • Remove the valve tappets and position them in order, to one side.

  1. CAUTION:
    CAUTION:The bolts can be re-used twice, center-punch the bolts.
    CAUTION:
    CAUTION:Remove the cylinder head bolts in the sequence shown.
    Remove the cylinder head.

  1. Using the special tool, remove the flywheel.
    • Discard the bolts.
  1. Remove the special tool.

  1. Remove the drain plug and the oil pan retaining bolts.
    • Allow the oil to drain into a suitable container.

  1. CAUTION:
    CAUTION:To prevent damage to the sealing surfaces, only use the special tool shown to remove the oil pan.
    NOTE:
    NOTE:Tighten the locknut against the oil pan and tap the special tool several times to release the oil pan from the lower crankcase.
    Using the special tool, remove the oil pan.

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

  1. Remove the oil pump.

  1. Remove the crankshaft rear oil seal carrier, crankshaft position (CKP) sensor and CKP bracket.

Disassembly and Assembly of Subassemblies > < In-vehicle Repair|Engine