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Focus RS 2003 (09.2002-)

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

Special Tool(s)

Slide Hammer

205-047 (15-011)

Flange Holding Wrench, Universal

205-072 (15-030A)

Mounting Bracket for 303-435

303-435-04 (21-064)

Locking Tool, Flywheel

303-254 (21-135)

Mounting Plate for 303-435-04

303-435-12 (21-150A)

Adapter for 205-047

303-633 (21-227)

Socket, Cylinder Head Bolt

303-392 (21-167)
General Equipment
Assembly stand
Oil filter strap wrench

Disassembly
  1. Remove the catalytic converter upper retaining bolts.

  1. Remove the catalytic converter retaining clamp (turbocharger heat shield shown removed for clarity).

  1. Remove the catalytic converter lower retaining bolts.

  1. Remove the catalytic converter lower bracket retaining bolts (catalytic converter shown removed for clarity).

  1. Remove the intermediate shaft center bearing bracket.

  1. Detach the turbocharger oil return line from the cylinder block.
    • Discard the gasket

  1. Disconnect the oil pressure switch electrical connector.

  1. Remove the oil pressure switch.

  1. Remove the generator.
    1. Disconnect the positive cable.
    1. Remove the bolt.
    1. Loosen the bolt.

  1. Remove the generator bracket.

  1. Remove the intake manifold (five bolts and two nuts).
    • Discard the gaskets.

  1. Using a suitable oil filter strap wrench, remove the oil filter.
    • Allow the oil to drain into a suitable container.
    • Discard the filter.

  1. Remove the oil cooler.
    • Discard the gasket.

  1. Detach the turbocharger oil supply line from the cylinder block.

  1. Install the mounting plate to the engine.

  1. Install the mounting bracket to the mounting plate.
  1. Attach the engine to the assembly stand and remove the engine lifting bracket.

  1. Detach the turbocharger coolant supply line from the cylinder head.

  1. Disconnect the wastegate control valve solenoid vacuum hose from the turbocharger.

  1. Remove the positive crankcase ventilation (PCV) heat shield retaining nut.

  1. Remove the PCV heat shield.
    • Remove the PCV heat shield retaining clip.

  1. Remove the exhaust manifold heat shield.

  1. Remove the turbocharger retaining bolts.
    • Discard the gasket.

  1. Remove the oil level indicator and tube.

  1. Remove the power steering pump bracket.
    1. Remove the bolts.
    1. Remove the nuts.
    • Discard the nuts.

  1. Remove the air conditioning (A/C) compressor bracket.

  1. Remove the exhaust manifold.
    • Discard the gasket.

  1. Remove the positive crankcase ventilation (PCV) housing.
    • Disconnect the hose.
    1. Discard the gasket.

  1. Remove the water pump pulley.

  1. Remove the accessory drive belt idler pulley.

  1. Remove the engine front mount bracket.

  1. Remove the timing belt upper cover.

  1. Install the special tool.

  1. Remove the crankshaft pulley.

  1. Remove the timing belt lower cover.

  1. Disconnect the spark plug electrical connectors.

  1. Remove the spark plugs.

  1. Remove the heat shield.
    1. Remove the nut.
    1. Loosen the nut and the bolts.

  1. NOTE:
    NOTE:Loosen the valve cover retaining bolts in a diagonal sequence.
    Remove the valve cover.

  1. Detension the timing belt.
    1. Loosen the bolt and turn the tensioner clockwise.
    1. Loosen the bolt a further four turns and unhook the timing belt tensioner.
  1. Remove the timing belt.
    • Discard the timing belt.

  1. Remove the timing belt idler pulley.

  1. Remove the timing belt tensioner.

  1. Remove the crankshaft timing pulley and the thrust washer.

  1. Remove the water pump.
    • Discard the gasket.

  1. Using the special tool, remove the camshaft pulleys.

  1. CAUTION:
    CAUTION:Loosen the camshaft bearing cap retaining bolts in the sequence shown.
    Remove the camshafts.
    • Remove the camshaft bearing cap retaining bolts evenly in several stages, two turns at a time.
    • Remove the camshaft oil seals.

  1. CAUTION:
    CAUTION:The cylinder head must be cooled to ambient temperature.
    CAUTION:
    CAUTION:Remove the cylinder head bolts in the sequence shown.
    Using the special tool, remove the cylinder head.
    • Discard the gasket.
  1. Remove the clutch disc and pressure plate. For additional information, refer to Section  308-01C Clutch.

  1. Using the special tool, remove the flywheel.
    • Discard the bolts.
  1. Remove the special tool.

  1. Remove the drain plug and the oil pan retaining bolts.
    • Allow the oil to drain into a suitable container.

  1. CAUTION:
    CAUTION:To prevent damage to the sealing surfaces, only use the special tool shown to remove the oil pan.
    NOTE:
    NOTE:Tighten the locknut against the oil pan and tap the special tool several times to release the oil pan from the lower crankcase.
    Using the special tool, remove the oil pan.

  1. Remove the lower crankcase.
    1. Remove the oil pickup tube.
    • Discard the gasket.
    1. Remove the lower crankcase retaining bolts.

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

  1. Remove the crankshaft position (CKP) sensor and mounting bracket.

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

Assembly > < In-vehicle Repair|Engine