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

Focus 2004.75 (07.2004-)

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

Special Tool(s)

Slide Hammer

205-047

Lifting Bracket, Engine

303-122

Socket, Cylinder Head Bolt

303-392

Locking Tool, Flywheel

303-393

Remover/Installer, Hose Clamp

303-397

Mounting Stand

303-435

Mounting Bracket for 303-435

303-435-06

Mounting Plate for 303-435-06

303-435-14A

Socket, Spark Plug

303-499

Adapter for 205-047

303-633

Locking-Tool

303-1054
General Equipment
Securing straps
Engine hoist
One bolt M10 x 40 mm
One bolt M10 x 45 mm
Oil filter strap wrench
All vehicles
  1. Remove the engine wiring harness.

  1. Attach the special tool to the engine.

  1. Install the special tool.

  1. Mount the engine on the mounting stand.

  1. Remove the special tool.

  1. Drain the engine.
    • Allow the oil to drain into a suitable container.

  1. Using a suitable oil filter strap wrench, remove the oil filter.
    • Discard the oil filter.

  1. Remove the oil cooler.

  1. Remove the generator.

  1. Remove the coolant pump pulley.

  1. Remove the engine front mount bracket.

  1. Remove the timing belt upper cover.

  1. Disconnect the spark plug electrical connectors and detach the spark plug wires from the valve cover.

  1. Remove the valve cover.

  1. Using the special tool, remove the spark plugs.

  1. Using the special tool, lock the flywheel.

  1. Remove the crankshaft pulley/vibration damper.
    • Discard the bolt.

  1. Remove the timing belt lower cover.
Vehicles built up to 04/2005
  1. Detension the timing belt by turning the automatic timing belt tensioner and using the special tool lock it in position.
    • Remove and discard the timing belt.

  1. Remove the automatic timing belt tensioner.
Vehicles built 04/2005 onwards
  1. Tension the timing belt tensioner and lock it in position using the special tool.
    • Remove and discard the timing belt.

  1. Remove the timing belt tensioner.
All vehicles
  1. CAUTION:
    CAUTION:Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from rotating.
    Remove the blanking plugs.

  1. CAUTION:
    CAUTION:Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from rotating.
    Remove the VCT elements.

  1. Remove the crankshaft timing belt pulley.

  1. Remove the timing belt rear cover.

  1. CAUTION:
    CAUTION:Keep the camshaft bearing caps and the camshafts in order for installation.
    Remove the camshafts.
    • Loosen the camshaft bearing cap retaining bolts and VCT bridge bolts in the sequence shown by one turn at a time until the camshaft are released.
    • Remove the camshaft bearing caps and the VCT bridge.
    • Remove and discard the camshaft seals.

  1. Disconnect the positive crankcase ventilation (PCV) hose from the PCV cover.

  1. Remove the oil level indicator and tube.

  1. Remove the intake manifold lower retaining bolts.

  1. Using the special tool, disconnect the thermostat housing to coolant shut off valve coolant hose from the thermostat housing.

  1. CAUTION:
    CAUTION:Remove the cylinder head bolts in the sequence shown.
    Using the special tool, remove the cylinder head.
    • Discard the gasket.

  1. CAUTION:
    CAUTION:Do not damage the coolant pump impeller.
    Remove the coolant pump.
    • Discard the gasket.

  1. Remove the oil pressure switch.

  1. Remove the thermostat housing.
    • Discard the gasket.

  1. Remove the knock sensors (KS).

  1. Remove the PCV cover.

  1. Remove the oil pan retaining bolts.

  1. CAUTION:
    CAUTION:In order to prevent damage to the sealing surfaces, only use the designated special tool to remove the oil pan. Do not use a chisel or screwdriver for removal.
    NOTE:
    NOTE:Tighten the lock nut against the oil pan and use several taps to release the oil pan from the cylinder block.
    Using the special tool, remove the oil pan.

  1. Remove the oil pump pickup tube.
    • Discard the gasket.

  1. Remove the oil pump.
    • Discard the gasket.
  1. Remove the clutch disc and pressure plate.
    For additional information, refer to: Clutch Disc and Pressure Plate (308-01 Clutch - Vehicles With: 5-Speed Manual Transaxle (iB5), Removal and Installation).

  1. Remove the flywheel.
    • Discard the bolts.
    • Remove the special tool.

  1. Remove the crankshaft position (CKP) sensor.

  1. Remove the CKP sensor bracket.

  1. Remove the crankshaft rear seal carrier.
    • Discard the crankshaft rear seal carrier.

  1. Remove the cylinder block from the mounting stand.
    • Remove the special tools.

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