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Ford Workshop Service and Repair Manuals

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Engine - Vehicles With: Automatic Transaxle > < Assembly|Engine

Focus 2004.75 (07.2004-)

Engine - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) - Engine—Vehicles With: Manual Transaxle Focus 2004.75 (07/2004-)
Installation

Special Tool(s)

Remover/Installer, Hose Clamp

303-397
General Equipment
Workshop table
Retaining straps
Engine hoist

Installation

All vehicles
WARNING:
WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.
  1. NOTE:
    NOTE:Using suitable retaining straps, secure the engine on the workshop table.
    Support the engine with wooden blocks.
  1. Install the transaxle.

  1. Install the transaxle upper retaining bolts.

  1. Install the transaxle left-hand retaining bolts.

  1. Install the transaxle right-hand retaining bolts.

  1. Install the transaxle lower retaining bolts.

  1. Install the starter motor.

  1. Install the wiring harness retaining bracket.
    • Attach the wiring harness to the retaining bracket.

  1. Position the workshop table under the vehicle and carefully lower the vehicle until the engine and transaxle assembly is in the correct position to install the engine mounts.

  1. NOTE:
    NOTE:Do not tighten the engine rear mount retaining bolt at this stage.
    Install the engine rear mount retaining bolt.
  1. Install the engine front mount.

  1. Install the engine front mount retaining studs.

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

  1. Attach the air conditioning compressor (A/C) line retaining bracket to the engine front mount.
  1. Remove the retaining straps from the transaxle.

  1. Connect the fuel supply line.

  1. Connect the evaporative emission (EVAP) valve vacuum line.
  1. Raise and support the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).
  1. Install the right-hand halfshaft.
    For additional information, refer to: Halfshaft RH (205-04 Front Drive Halfshafts, Removal and Installation).
  1. Install the left-hand halfshaft.
    For additional information, refer to: Halfshaft LH (205-04 Front Drive Halfshafts, Removal and Installation).

  1. Install the engine support insulator.

  1. Install the crashbox.
    1. Bolt M10x16
    1. Bolt M10x25

  1. Attach the air conditioning (A/C) compressor to the oil pan.

  1. Connect the A/C compressor electrical connector.
  1. Install the A/C compressor belt.
    For additional information, refer to: Air Conditioning (A/C) Compressor Belt - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (303-05 Accessory Drive, Removal and Installation).

  1. Install the A/C compressor cover.

  1. Install the A/C line retaining bracket.

  1. Install the exhaust manifold lower retaining nuts (engine shown removed for clarity).
  1. Lower the vehicle.

  1. Tighten the engine rear mount retaining bolt.

  1. Tighten the engine front mount retaining nuts and retaining bolts.

  1. NOTE:
    NOTE:Install a new exhaust manifold gasket.
    Tighten the exhaust manifold retaining nuts (engine shown removed for clarity).

  1. Install the exhaust manifold heat shield (engine shown removed for clarity).

  1. CAUTION:
    CAUTION:If brake fluid is spilt on the paintwork, the affected area must be immediately washed down with cold water.
    Connect the clutch slave cylinder supply line to the clutch slave cylinder.
    • Attach the clutch slave cylinder supply line to the bracket.
    • Install the spring clip.

  1. Attach the ground cable to the transaxle.

  1. Connect the reversing lamp switch electrical connector.

  1. Attach the gearshift cables to the cable brackets.
    1. Attach the shift cable to the cable bracket and turn the abutment sleeve clockwise.
    1. Attach the selector cable to the cable bracket and turn the abutment sleeve clockwise.

  1. Attach the gearshift cables to the transaxle.
    1. Press the locking tab and attach the shift cable to the transaxle shift lever.
    1. Press the locking tab and attach the selector cable to the transaxle selector lever.

  1. Connect the brake booster vacuum line to the intake manifold.

  1. Install the coolant expansion tank.

  1. Using the special tool, connect the coolant hose to the coolant expansion tank.

  1. Connect the coolant hose.

  1. Using the special tool, connect the coolant hose to the coolant outlet connector.

  1. Connect the catalyst monitor sensor electrical connector.

  1. Connect the heated oxygen (HO2S) sensor electrical connectors.

  1. Connect the engine wiring harness electrical connector.

  1. Install the central junction box (CJB) cover.

  1. Attach the ground cables to the wheel housing.
  1. Adjust the gearshift cables.
    For additional information, refer to: Gearshift Cable Adjustment - Vehicles With: 5-Speed Manual Transaxle (MTX-75) (308-00 Manual Transmission/Transaxle and Clutch - General Information, General Procedures).
  1. Bleed the hydraulic clutch system.
    For additional information, refer to: Clutch System Bleeding (308-00 Manual Transmission/Transaxle and Clutch - General Information, General Procedures).
  1. Install the battery tray.
    For additional information, refer to: Battery Tray - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma)/1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (414-01 Battery, Mounting and Cables, Removal and Installation).

  1. Connect the powertrain control module (PCM) electrical connectors.

  1. Connect the battery positive lead to the battery positive cable terminal clamp.
  1. Connect the battery ground cable.
    For additional information, refer to: Battery Disconnect (414-01 Battery, Mounting and Cables, General Procedures).
  1. Install the air cleaner.
    For additional information, refer to: Air Cleaner - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (303-12 Intake Air Distribution and Filtering, Removal and Installation).
  1. Fill and bleed the cooling system.
    For additional information, refer to: Cooling System Draining, Filling and Bleeding (303-03 Engine Cooling - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), General Procedures).

  1. Install the engine cover.
Vehicles with global closing
  1. Initialize the window regulator motors.
    For additional information, refer to: Door Window Motor Initialization (501-11 Glass, Frames and Mechanisms, General Procedures).

Engine - Vehicles With: Automatic Transaxle > < Assembly|Engine