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In-vehicle Repair|Disassembly > < Crankshaft Rear Seal

Focus RS 2003 (09.2002-)

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

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. Release the fuel system pressure. For additional information, refer to Section  310-00A Fuel System - General Information.
  1. Remove the battery tray. For additional information, refer to Section  414-01 Battery, Mounting and Cables.
  1. Detach the positive and the negative leads from the battery clamps
  1. Remove the charge air cooler. For additional information, refer to Section  303-12 Intake Air Distribution and Filtering.
  1. Remove the intake air cleaner. For additional information, refer to Section  303-12 Intake Air Distribution and Filtering.
  1. Drain the cooling system. For additional information, refer to Section  303-03 Engine Cooling.
  1. Lower the vehicle.

  1. Disconnect the ground cable from the body.

  1. Loosen the strut and spring assembly top mount nuts by three turns on both sides.

  1. Disconnect the vacuum hose from the throttle body intake housing.

  1. Disconnect the vacuum hoses from the throttle body.

  1. Disconnect the hose and the intake air temperature (IAT) sensor electrical connector.

  1. Detach the accelerator cable from the throttle body and position it to one side.
    1. Detach the accelerator outer cable from the throttle body bracket.
    1. Detach the accelerator inner cable from the throttle body lever.

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

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

  1. Disconnect the power steering pressure (PSP) switch electrical connector.

  1. Disconnect the supply hose from the power steering pump.
    • Allow the fluid to drain into a suitable container.
  1. Separate the cable ties.

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

  1. Disconnect the generator electrical connector.

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

  1. Disconnect the reversing lamp switch electrical connector.
  1. Unclip the wiring loom from the engine.

  1. Disconnect the vacuum hoses from the throttle body.

  1. Disconnect the brake booster vacuum pipe.

  1. Disconnect the fuel supply and return lines from the fuel rail.

  1. Disconnect the ground cable from the engine front lifting eye.

  1. Detach the thermostat housing from the cylinder head.
    • Discard the thermostat housing O-ring seal.

  1. Disconnect the coolant hose from the turbocharger.

  1. Using the special tool, disconnect the coolant hose from the water pump.

  1. Detach the gearshift cables from the transaxle.
    1. Detach the gearshift cable (colored white) and the selector cable (colored black) from the selector levers.
    1. Turn the abutment collars clockwise and detach the cables from the bracket.

  1. Detach the power steering supply line from the power steering pump.
    • Allow the fluid to drain into a suitable container.
  1. Remove the accessory drive belt. For additional information, refer to Section  303-05 Accessory Drive.

  1. Detach the air conditioning (A/C) compressor from the bracket and secure it on the radiator crossmember.

  1. Disconnect the coolant hose from the coolant pipe.

  1. Remove the flexible exhaust pipe.
    • Discard the gaskets.
  1. Remove the crossmember. For additional information, refer to Section  502-00 Uni-Body, Subframe and Mounting System.

  1. CAUTION:
    CAUTION:Support the halfshaft. The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.
    CAUTION:
    CAUTION:Do not damage the halfshaft oil seal.
    NOTE:
    NOTE:Plug the transaxle to prevent oil loss or dirt ingress.
    Detach the right-hand halfshaft and the intermediate shaft from the transaxle and secure it to one side.
    • Discard the center bearing locknuts.
    • Allow the oil to drain into a suitable container.

  1. CAUTION:
    CAUTION:Support the halfshaft. The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.
    CAUTION:
    CAUTION:Do not damage the halfshaft oil seal.
    NOTE:
    NOTE:Plug the transaxle to prevent oil loss or dirt ingress.
    Using a suitable punch, detach the left-hand halfshaft from the transaxle and secure it to one side.
    • Discard the snap ring.
    • Allow the oil to drain into a suitable container.

  1. Disconnect the vehicle speed sensor (VSS) electrical connector.

  1. WARNING:
    WARNING:Support the engine and transaxle assembly on wooden blocks and secure it with suitable securing straps.
    Carefully lower the vehicle until the engine and transaxle assembly is supported by the workshop table.

  1. Remove the engine rear mount center retaining nut.
    • Discard the nut.

  1. Remove the engine rear mount.

  1. Detach the coolant expansion tank from the bracket and position it to one side.

  1. Remove the engine front mount.
  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.

  1. Remove the transaxle upper retaining bolts.

  1. Remove the starter motor retaining bolts.

  1. Remove the starter motor.

  1. Remove the transaxle left-hand retaining bolts.

  1. Remove the transaxle right-hand retaining bolts.
  1. Remove the transaxle.

In-vehicle Repair|Disassembly > < Crankshaft Rear Seal