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In-vehicle Repair|Disassembly > < Crankshaft Rear Seal

Focus 2004.75 (07.2004-)

Engine - 2.0L Duratorq-TDCi (DW) Diesel - Engine—Vehicles With: Manual Transmission Focus 2004.75 (07/2004-)
Removal

Special Tool(s)

Lifting Bracket, Engine

303-122

Remover/Installer, Hose Clamp

303-397
General Equipment
Retaining strap
Workshop table
Engine hoist
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.
WARNING:
WARNING:This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow these instructions may result in personal injury.
  1. Using Datalogger in WDS, check that the fuel pressure has dropped to zero and that the fuel temperature is below 30°C.
  1. Remove the cowl panel grille.
    For additional information, refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).

  1. NOTE:
    NOTE:The engine upper cover is held in place by three ball clips. The ball clips are not vertical, but are angled backwards by approximately 20 degrees.
    Location of the engine upper cover ball clips.

  1. CAUTION:
    CAUTION:Contact of the engine upper cover with the cowl panel may cause damage (scratches) on the engine upper cover. If the ambient temperature is below 0° C, detach the engine upper cover with extreme caution. Failure to follow this instruction may cause the engine upper cover to be damaged.
    NOTE:
    NOTE:Only remove and install the engine upper cover in the sequence shown.
    Remove the engine upper cover.
    • Detach the engine upper cover ball clips in the sequence shown.
  1. Remove the battery tray.
    For additional information, refer to: Battery Tray - 1.6L Duratorq-TDCi (DV) Diesel/1.8L Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel (414-01 Battery, Mounting and Cables, Removal and Installation).
  1. Remove the intake air cleaner.
    For additional information, refer to: Air Cleaner - 2.0L Duratorq-TDCi (DW) Diesel (303-12A Intake Air Distribution and Filtering, Removal and Installation).
  1. Remove the front drive halfshafts. For additional information, refer to: (205-04 Front Drive Halfshafts)
    Halfshaft RH - 3-Door (Removal and Installation),
    Front Halfshaft LH (Removal and Installation).

  1. Remove the fender splash shield.
  1. Remove the charge air cooler.
    For additional information, refer to: Charge Air Cooler - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel (303-12A Intake Air Distribution and Filtering, Removal and Installation).
  1. Remove the radiator.
    For additional information, refer to: Radiator (303-03G Engine Cooling - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
  1. Remove the catalytic converter.
    For additional information, refer to: Catalytic Converter - 2.0L Duratorq-TDCi (DW) Diesel (309-00A Exhaust System, Removal and Installation).

12. Remove the components in the order indicated in the following illustration(s) and table(s).

 
Item
Part Number
Description
1
-
Coolant expansion tank hoses
See Removal Detail
2
-
Coolant expansion tank
3
-
Fuel supply line and fuel return line
See Removal Detail
4
-
Air intake pipe

 
Item
Part Number
Description
5
-
Battery junction box (BJB) cover
6
-
Engine wiring harness electrical connector
7
-
Coolant regulator valve electrical connector
8
-
Engine ground cable

 
Item
Part Number
Description
9
-
Powertrain control module (PCM) cover
10
-
PCM security bracket (if equipped)
See Removal Detail
11
-
PCM electrical connectors
See Removal Detail
12
-
PCM

 
Item
Part Number
Description
13
-
Brake booster vacuum hose
14
-
Coolant degas hose
15
-
Thermostat housing upper coolant hose
See Removal Detail
16
-
Thermostat housing lower coolant hose
See Removal Detail

 
Item
Part Number
Description
17
-
Clutch slave cylinder supply line
See Removal Detail
18
-
Gearshift cables
See Removal Detail

 
Item
Part Number
Description
19
-
Accessory drive belt
See Removal Detail
20
-
Air conditioning (A/C) compressor electrical connector
21
-
A/C compressor
See Removal Detail

 
Item
Part Number
Description
22
-
Charge air cooler intake pipe
23
-
Engine support insulator

 
Item
Part Number
Description
24
-
Heater core hose
25
-
Engine front mount
See Removal Detail
26
-
Engine rear mount
See Removal Detail

 
Item
Part Number
Description
27
-
Starter motor power supply
28
-
Starter motor
29
-
Transaxle ground cable

 
Item
Part Number
Description
30
-
Transaxle

 
Item
Part Number
Description
31
-
Transaxle retaining bolts

Removal Details

Item 1 : Coolant expansion tank hoses
  1. Using the special tool, remove the coolant expansion tank hoses.

Item 3 : Fuel supply line and fuel return line

  1. Disconnect the fuel supply line and fuel return line quick release coupling.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

Item 10 : PCM security bracket (if equipped)

  1. File a flat across the PCM security bracket welded nut.

  1. Remove the PCM security bracket sheer bolt.
    • Drill a 2mm pilot hole 3mm from the outer edge of the security bracket welded nut at an angle of approximately 2°.
    • Drill a 5mm hole in the security bracket welded nut and remove the security bracket sheer bolt.
  1. Slide the security bracket off of the PCM.

Item 11 : PCM electrical connectors
  1. Detach the PCM electrical connectors in the sequence shown.

Item 15 : Thermostat housing upper coolant hose
  1. Using the special tool, detach the thermostat housing upper coolant hose from the thermostat housing.

  1. Using the special tool, remove the thermostat housing upper coolant hose.

Item 16 : Thermostat housing lower coolant hose
  1. Using the special tool, detach the thermostat housing lower coolant hose from the thermostat housing.

  1. Using the special tool, remove the thermostat housing lower coolant hose.

Item 17 : Clutch slave cylinder supply line
  1. CAUTION:
    CAUTION:If brake fluid is spilt on the paintwork, the affected area must be immediately washed down with cold water.
    Detach the clutch slave cylinder supply line from the clutch slave cylinder.
    • Detach the clutch slave cylinder supply line from the bracket.
    • Remove the spring clip.

Item 18 : Gearshift cables
  1. Detach the gearshift cables from the transaxle.
    1. Detach the gearshift cable and the selector cable from the selector levers.
    1. Press the tabs together and detach the cables from the bracket.

Item 19 : Accessory drive belt

  1. Remove the accessory drive belt.
    For additional information, refer to: Accessory Drive Belt - 2.0L Duratorq-TDCi (DW) Diesel (303-05A Accessory Drive, Removal and Installation).

Item 21 : A/C compressor
  1. CAUTION:
    CAUTION:Support the A/C compressor before removing the retaining bolts and secure it to one side to prevent load being placed on the refrigerant lines.
    Detach the A/C compressor from the mounting bracket and secure it to one side.

Item 25 : Engine front mount
  1. WARNING:
    WARNING:Support the engine and transaxle assembly on wooden blocks and secure it with a retaining strap. Failure to follow these instructions may result in personal injury.
    Position the workshop table under the vehicle and carefully lower the vehicle, until the engine and transaxle assembly is in the correct position to remove the engine mounts.

  1. Remove the engine front mount.
    • Discard the nuts.

Item 26 : Engine rear mount
  1. Remove the engine rear mount.
    • Discard the nuts.
  1. Raise the vehicle and remove the engine and transaxle assembly.

  1. Using the special tool, attach the engine and transaxle assembly to the engine hoist.
    • Remove the retaining strap.

In-vehicle Repair|Disassembly > < Crankshaft Rear Seal