ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

ABOUT US
Thermostat - 2.0L Duratec-ST (Zetec) > < Thermostat - 1.6L Zetec-E (Zetec)-1.8L Zetec-E (Zetec)-2.0L Zetec-E (Zetec)

Focus 1999 (08.1998-12.2004)

Engine Cooling - Thermostat—1.8L Diesel Focus 1999 (08/1998-12/2004)
Removal and Installation

Special Tool(s)

Remover/Installer, Cooling Hose Clamp 303-397 (24-003)

Removal

  1. Drain the cooling system.
    For additional information, refer to: Cooling System Draining, Filling and Bleeding (303-03 Engine Cooling, General Procedures).

  1. Remove the air deflector.

  1. NOTE:
    NOTE:Make a note of the orientation of the retaining clamp.
    Disconnect the charge air cooler intake pipe.
    • Discard the retaining clamp.

  1. NOTE:
    NOTE:Make a note of the orientation of the retaining clamp.
    Disconnect the charge air cooler outlet pipe and the intake air temperature (IAT) sensor electrical connector.
    • Discard the retaining clamp.

  1. NOTE:
    NOTE:Make a note of the orientation of the retianing clamps.
    Remove the charge air cooler outlet pipe.
    1. Loosen the clamps.
    1. Remove the nut.
    • Discard the retaining clamps.

  1. NOTE:
    NOTE:Make a note of the orientation of the retaining clamp.
    Remove the charge air cooler pipe to intake manifold hose.
    • Discard the hose and the clamps.

  1. Remove the charge air cooler.

  1. Using the special tool disconnect the coolant hose.

  1. Remove the thermostat cover.

  1. Remove the thermostat.

  1. Remove and discard the thermostat O-ring seal.

Installation

CAUTION:
CAUTION:Make sure that the inside of the charge air cooler intake pipe and outlet pipe ends are clean and free from any oil residue as this will reduce the installation grip of the pipes to the charge air cooler. Failure to follow this instruction may result in damage to the engine.
CAUTION:
CAUTION:Make sure that a new charge air cooler outlet pipe to turbocharger hose and all new charge air cooler hose retaining clamps are installed. Failure to follow this instruction may result in damage to the engine.
  1. NOTE:
    NOTE:Install a new thermostat O-ring seal.
    To install, reverse the removal procedure.

NOTE:
NOTE:Install a new charge air cooler pipe to intake manifold hose and retaining clamps.
NOTE:
NOTE:Make sure the retaining clamps are in the same orientation as when removed.

NOTE:
NOTE:Install new retaining clamps.
NOTE:
NOTE:Make sure the retaining clamps are in the same orientation as when removed.

Thermostat - 2.0L Duratec-ST (Zetec) > < Thermostat - 1.6L Zetec-E (Zetec)-1.8L Zetec-E (Zetec)-2.0L Zetec-E (Zetec)