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303-08C Engine Emission Control - 1.6L Duratorq-TDCi (DV) Diesel|Specifications > < Crankcase Vent Oil Separator
Engine Emission Control - 1.6L Duratorq-TDCi (DV) Diesel - Exhaust Gas Recirculation (EGR) Cooler Focus 2004.75 (07/2004-)
Removal and Installation

Special Tool(s)

Remover/Installer, Cooling Hose Clamp

303-397 (24-003)

  1. Drain the cooling system.
    For additional information, refer to: Cooling System Draining, Filling and Bleeding (303-03D Engine Cooling - 1.6L Duratorq-TDCi (DV) Diesel, General Procedures).
  1. NOTE:
    NOTE:Make sure that the windshield wiper motor is in the park position.
    Disconnect the battery ground cable.
    For additional information, refer to: Battery Disconnect (414-01 Battery, Mounting and Cables, General Procedures).

  1. Remove the engine upper cover.

  1. Detach the brake fluid reservoir from the bulkhead extension panel.

  1. Remove the windshield wiper arms.

  1. Remove the cowl panel grille.
    1. Detach the cowl panel grille retaining clips.
    1. Detach the cowl panel grille from the windshield glass lower weatherstrip and remove.

  1. Remove the bulkhead extension panel.
    1. Remove the bulkhead extension panel retaining screws.
    1. Detach the bulkhead exstension panel retaning clips.

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

 
Item
Part Number
Description
1
-
Fuel injector harness retaining bolts
2
-
Fuel injector electrical connectors
4
-
Coolant bypass tube to EGR cooler coolant hose
5
-
Heater core to EGR cooler coolant hose retaining clamp
See Removal Detail
6
-
Heater core to EGR cooler coolant hose
7
-
Glow plug wire support bracket
8
-
EGR cooler to EGR tube retaining clamp
See Removal Detail
See Installation Detail
9
-
EGR cooler to EGR tube retaining clamp
See Removal Detail
See Installation Detail
10
-
EGR tube retaining bolts
11
-
EGR tube
12
-
EGR cooler

9. To install, reverse the removal procedure.

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

Removal Details

Item 3 : Coolant bypass tube to EGR cooler coolant hose retaining clamp

  1. Using the special tool, detach the coolant bypass tube to EGR cooler coolant hose retaining clamp.

Item 5 : Heater core to EGR cooler coolant hose retaining clamp

  1. Using the special tool, detach the heater core to EGR cooler coolant hose retaining clamp.

Item 8 : EGR cooler to EGR tube retaining clamp

  1. Make a note of the position of the EGR cooler retaining clamp before removal.

Item 9 : EGR cooler to EGR tube retaining clamp

  1. Make a note of the position of the EGR cooler to EGR tube clamp before removal.

Installation Details

Item 9 : EGR cooler to EGR tube retaining clamp

  1. Install the EGR cooler to EGR tube clamp in the same position as when removed.

Item 8 : EGR cooler to EGR tube retaining clamp

  1. Install the EGR cooler retaining clamp in the same position as when removed.

303-08C Engine Emission Control - 1.6L Duratorq-TDCi (DV) Diesel|Specifications > < Crankcase Vent Oil Separator