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303-01B Engine - 1.6L Duratec-16V Ti-VCT (Sigma)|Engine > < Assembly|Engine

Focus 2004.75 (07.2004-)

Engine - 1.6L Duratec-16V Ti-VCT (Sigma) - Engine Focus 2004.75 (07/2004-)
Installation

Special Tool(s)

Lifting Bracket, Engine

303-122

Remover/Installer, Hose Clamp

303-397
General Equipment
Retaining straps
Workshop table
Workshop hoist
Materials
Name
Specification
Grease
SA-M1C9107-A 
WARNING:
WARNING:Do not smoke or use any kind of naked flame 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.

 
Item
Part Number
Description
1
-
Transmission left-hand retaining bolt
See Installation Detail
2
-
Starter motor bolts
See Installation Detail

 
Item
Part Number
Description
3
-
Front engine mounting
See Installation Detail
4
-
Rear engine mounting
See Installation Detail

 
Item
Part Number
Description
5
-
Fuel supply line
6
-
Fuel evaporation system (EVAP) vacuum hose
7
-
Heater core coolant hose
See Installation Detail
8
-
Coolant distribution connection hose
See Installation Detail
9
-
Heater core coolant hose
See Installation Detail
10
-
Coolant outlet connection hose
See Installation Detail
11
-
Brake servo vacuum hose
12
-
Clutch slave cylinder pressure line
See Installation Detail

 
Item
Part Number
Description
13
-
Engine roll restrictor rubber mountings
See Installation Detail
14
-
Power steering pump
See Installation Detail
15
-
Gearshift cables
See Installation Detail
16
-
Gearshift cable cover

 
Item
Part Number
Description
17
-
Exhaust manifold bolt and nuts
See Installation Detail
18
-
Catalytic converter bracket bolts
19
-
Exhaust pipe rubber insulators
20
-
Flexible exhaust pipe nuts
See Installation Detail
21
-
Exhaust system heat shield
22
-
Exhaust system heat shield bolts
All vehicles
  1. Install the left-hand front driveshaft.
    For additional information, refer to: Front Halfshaft LH (205-04 Front Drive Halfshafts, Removal and Installation).

  1. Attach the ground cable to the cylinder block.
  1. Install the right-hand front driveshaft together with the intermediate shaft.
    For additional information, refer to: Rechte Antriebswelle (205-04 Vorderradantriebswellen, Removal and Installation).

  1. Install the crash box.
    1. Insert the M10 x 16 mm bolt.
    1. Insert the M10 x 25 mm bolts.

  1. Install the cross brace.

  1. Connect the heated oxygen sensor (HO2S) and the left-hand catalyst monitor sensor connectors.

  1. Connect the HO2S and the right-hand catalyst monitor sensor connectors.

  1. Attach the central junction box (CJB) connector.

  1. Install the CJB cover.

  1. Attach the ground cable to the wheelhouse.

  1. Attach the coolant expansion tank to the wheel housing.

  1. Connect the coolant hose to the coolant expansion tank using the special tool.

  1. Attach the power steering fluid reservoir to the bracket.
Vehicles without air conditioning
  1. Install the auxiliary drive belt.
    For additional information, refer to: Accessory Drive Belt - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Vehicles Without: Air Conditioning (303-05A Accessory Drive, Removal and Installation).

  1. Attach the lower radiator hose to the radiator using the special tool.
Vehicles with air conditioning
  1. Install the auxiliary drive belt.
    For additional information, refer to: Accessory Drive Belt - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Vehicles With: Air Conditioning (303-05A Accessory Drive, Removal and Installation).
  1. Install the radiator.
    For additional information, refer to: Radiator (303-03A Engine Cooling - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma), Removal and Installation).

  1. Attach the A/C compressor to the bracket.
    • Attach the A/C clutch connector.
All vehicles
  1. Bleed the clutch system.
    For additional information, refer to: Clutch System Bleeding (308-00 Manual Transmission/Transaxle and Clutch - General Information, General Procedures).

  1. Attach the battery positive lead to the battery terminal.
  1. Install the battery tray and the battery.
    For additional information, refer to: Battery - 1.4L Duratec-16V (Sigma)/1.6L (Z6)/1.6L Duratec-16V (Sigma)/1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (414-01 Battery, Mounting and Cables, Removal and Installation).
Vehicles with global closing
  1. Initialize the window winder motors.
    For additional information, refer to: Door Window Motor Initialization (501-11 Glass, Frames and Mechanisms, General Procedures).

Installation Details

Item 1 : Transmission left-hand retaining bolt
  1. Attach the engine to the workshop hoist using the special tool.
  1. CAUTION:
    CAUTION:Ensure that the two guide sleeves are installed.
    Attach the transmission to the engine.

  1. Install the transmission lower retaining bolts.

  1. NOTE:
    NOTE:Support the engine / transmission assembly with suitable wooden blocks.
    Secure the engine / transmission assembly on the workshop table using suitable retaining straps.

  1. Install the transmission right-hand retaining bolts.

  1. Install the transmission upper retaining bolts.

Item 2 : Starter motor bolts
  1. Attach the battery positive lead and the ignition switch cable to the starter motor.

Item 3 : Front engine mounting
  1. Position the workshop table under the vehicle and lower the vehicle until the engine mountings can be installed.

  1. NOTE:
    NOTE:Install new front engine mounting nuts.
    NOTE:
    NOTE:Do not fully tighten the front engine mounting at this stage.
    Install the front engine mounting.

Item 4 : Rear engine mounting
  1. Clip in the transmission breather.

Item 7 : Heater core coolant hose
  1. Connect the heater core coolant hose.
    1. Lock the catch by turning clockwise

Item 8 : Coolant distribution connection hose
  1. Attach the coolant hose to the coolant distribution connection using the special tool.

Item 9 : Heater core coolant hose
  1. Attach the coolant hose to the coolant distribution pipe using the special tool.

Item 10 : Coolant outlet connection hose
  1. Connect the coolant hose to the coolant outlet connection using the special tool.

Item 12 : Clutch slave cylinder pressure line
  1. CAUTION:
    CAUTION:If brake fluid comes into contact with the paintwork, rinse off the affected areas with cold water without delay.
    Attach the clutch slave cylinder pressure line to the clutch slave cylinder.
    • Attach the clutch slave cylinder pressure line to the bracket.
    • Install the spring clip.

Item 13 : Engine roll restrictor rubber mountings
  1. Install the engine roll restrictors.

  1. Tighten the front engine mounting nuts and bolts.

Item 14 : Power steering pump
  1. Attach the power steering pump to the bracket.

Item 15 : Gearshift cables
  1. Attach the gearshift cables to the bracket and turn the abutment sleeves counter-clockwise.
  1. Adjust the gearshift cables.
    For additional information, refer to: Schaltseilzug einstellen - Fahrzeuge ausgestattet mit 5-Gang Schaltgetriebe (iB5) (308-00 Schaltgetriebe und Kupplung - Allgemeine Informationen, General Procedures).

Item 17 : Exhaust manifold bolt and nuts

  1. NOTE:
    NOTE:Install a new exhaust manifold gasket.
    Coat the bolt and nuts with grease and install.

Item 20 : Flexible exhaust pipe nuts

  1. NOTE:
    NOTE:Install a new flange gasket.
    Coat the flexible pipe nuts with grease and install.

  1. Remove the support sleeve.

303-01B Engine - 1.6L Duratec-16V Ti-VCT (Sigma)|Engine > < Assembly|Engine