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303-01F Engine - 2.0L Duratec-RS (Zetec)|Specifications > < Assembly|Engine

Focus RS 2003 (09.2002-)

Engine - 2.0L Duratec-RS (Zetec) - Engine Focus RS 2003 (09/2002-)
Installation

Special Tool(s)

Lifting Bracket, Engine

303-122 (21-068A)

Remover/Installer Cooling Hose Clamp

303-397 (24-003)
General Equipment
Workshop table
Securing straps
Engine hoist
Wooden blocks
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 mixtures are always present and may ignite. Failure to follow these instructions may result in personal injury.
  1. WARNING:
    WARNING:Support the engine and transaxle assembly on wooden blocks and secure it with suitable securing straps.
    Using the special tool and the engine hoist, position the engine and transaxle assembly on the workshop table.

  1. Install the transaxle left-hand retaining bolts.

  1. Install the transaxle right-hand retaining bolts.

  1. Install the transaxle upper retaining bolts.

  1. Install the starter motor.

  1. Install the starter motor retaining bolts.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Position the engine and transaxle assembly in the engine compartment.
    • Carefully lower the vehicle.

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

  1. NOTE:
    NOTE:Do not tighten the engine rear mount retaining nuts at this stage.
    NOTE:
    NOTE:Install a new rear mount center retaining nut.
    Install the engine rear mount.
  1. Remove the workshop table.

  1. CAUTION:
    CAUTION:Support the halfshaft. The inner joint must not be bent at more than 18 degrees. The outer joint must not be bent at more than 45 degrees.
    CAUTION:
    CAUTION:Do not damage the halfshaft oil seal.
    NOTE:
    NOTE:Install new intermediate shaft center bearing locknuts.
    Attach the right-hand halfshaft and the intermediate shaft to the transaxle.

  1. CAUTION:
    CAUTION:Support the halfshaft. The inner joint must not be bent at more than 18 degrees. The outer joint must not be bent at more than 45 degrees.
    CAUTION:
    CAUTION:Do not damage the halfshaft oil seal.
    CAUTION:
    CAUTION:Make sure the snap ring is correctly seated.
    NOTE:
    NOTE:Install a new snap ring.
    Attach the left-hand halfshaft to the transaxle.
  1. Install the crossmember. For additional information, refer to Section  502-00 Uni-Body, Subframe and Mounting System.

  1. NOTE:
    NOTE:Install new exhaust flange gaskets.
    Install the exhaust flexible pipe.

  1. Connect the coolant hose to the coolant pipe.

  1. Attach the air conditioning (A/C) compressor to the bracket.
  1. Install the accessory drive belt. For additional information, refer to Section  303-05 Accessory Drive.

  1. Attach the power steering pump supply line to the power steering pump.
  1. Check the transaxle fluid level and top up with manual transmission fluid, if necessary. For additional information, refer to Section  303-01F Engine.
  1. Lower the vehicle.

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

  1. Tighten the engine rear mount nuts.

  1. Using the special tool, connect the coolant hose to the water pump.

  1. Attach the power steering reservoir to the bracket.

  1. Attach the coolant expansion tank to the bracket.
  1. Clip the wiring harness to the engine.

  1. NOTE:
    NOTE:Install a new thermostat housing O-ring seal.
    Attach the thermostat housing to the cylinder head.

  1. Attach the gearshift cables to the retaining bracket and turn the abutment sleeves counterclockwise.

  1. Connect the coolant hose to the turbocharger.

  1. Connect the fuel supply and return lines to the fuel rail.

  1. Connect the ground cable to the engine front lifting eye.

  1. Connect the brake booster vacuum pipe.

  1. Connect the vacuum hose to the throttle body.

  1. Connect the reversing lamp switch electrical connector.

  1. CAUTION:
    CAUTION:If brake fluid is spilt on the paintwork, the affected area must be immediately washed down with cold water.
    NOTE:
    NOTE:Make sure the spring clip is correctly seated.
    Connect the clutch slave cylinder supply line to the transaxle and install the spring clip.

  1. Using the special tool, connect the supply hose to the power steering pump.

  1. Connect the PSP switch electrical connector.

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

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

  1. Connect the generator electrical connector.

  1. Connect the electronic ignition (EI) coil electrical connector.

  1. Attach the accelerator cable to the throttle body.
    1. Attach the accelerator outer cable to the throttle body bracket.
    1. Attach the accelerator inner cable to the throttle body lever.

  1. Connect the intake temperature sensor electrical connector.

  1. Connect the vacuum hose to the throttle body intake housing.

  1. Connect the vacuum hoses to the throttle body.

  1. Connect the ground cable to the body.

  1. Tighten the strut and spring assembly upper mount retaining nuts on both sides (left-hand side shown).
  1. Bleed the hydraulic clutch system. For additional information, refer to Section  308-00 Manual Transmission/Transaxle and Clutch - General Information.

  1. Install the battery tray. For additional information, refer to Section  414-01 Battery, Mounting and Cables.
  1. Attach the positive and negative lead to the battery clamps.
  1. Adjust the gearshift cables. For additional information, refer to Section  308-00 Manual Transmission/Transaxle and Clutch - General Information.
  1. Install the charge air cooler. For additional information, refer to Section  303-12 Intake Air Distribution and Filtering.
  1. Install the intake air cleaner. For additional information, refer to Section  303-12 Intake Air Distribution and Filtering.
  1. Fill and bleed the engine cooling system. For additional information, refer to Section  303-03 Engine Cooling.

303-01F Engine - 2.0L Duratec-RS (Zetec)|Specifications > < Assembly|Engine