General Equipment Ford Focus I рестайлинг

General Equipment

SPECIAL TOOL SPECIFICATIONS

Scheme 781

Scheme 782

Scheme 783

Scheme 784

Scheme 785

1. Remove the air cleaner housing. Disconnect electrical connector of the mass air flow (MAF) sensor. Detach the intake hose. Remove the air cleaner housing from the rubber bushing.
2. Disconnect the heated oxygen sensor (HO2S) electrical connector.
3. Remove the heat shield. Remove the nuts and the power steering high pressure tube. Remove the nuts and the heat shield.
4. Remove the exhaust gas recirculation (EGR) tube.
5. Loosen the EGR tube fitting approximately three turns.
6. Remove the catalytic converter (TWC). For additional information, refer to «EXHAUST SYSTEM»(ref-207777) .
7. Lower the vehicle.
8. Remove the nuts, the exhaust manifold and the gasket. Discard the gasket.

Scheme 786

Scheme 787

Scheme 788

Scheme 789

Scheme 790

1. Install the exhaust manifold and a new gasket.
2. Raise the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
3. Install the TWC. For additional information, refer to «EXHAUST SYSTEM»(ref-207777) .
4. Install the EGR-tube and install the nuts.
5. Tighten the EGR-Tube nut.
6. Install the heat shield. Position the heat shield and install the nuts. Install the power steering pressure tube and install the nuts.
7. Connect the heated oxygen sensor (HO2S) electrical connector.
8. Install the air cleaner housing (ACL) Connect the MAF electrical connector. Attach the intake hose.
9. Connect the battery ground lead.

GENERAL EQUIPMENT SPECIFICATIONS

MATERIAL SPECIFICATIONS

Scheme 791

Scheme 792

Scheme 793

Scheme 794

Scheme 795

Scheme 796

Scheme 797

Scheme 798

Scheme 799

Scheme 800

Scheme 801

Scheme 802

Scheme 803

Scheme 804

Scheme 805

Scheme 806

Scheme 807

1. Remove the air cleaner housing. Disconnect the mass air flow (MAF) electrical connector. Detach the intake hose. Remove the air cleaner housing from the rubber bushing.
2. Remove the battery tray and detach the ground cable. Detach and separate the connector. Detach the wiring harness. Unscrew the bolts. Detach the positive and negative cables.
3. Detach the accelerator cable. Unhook the cable. Pull off the plastic clip and lay the accelerator cable to one side.
4. Remove the speed control cable. Unhook the cable. Pull off the plastic clip and lay the speed control cable to one side.
5. Disconnect the both powertrain control module (PCM) connectors.
6. Disconnect the heated oxygen sensor (HO2S) electrical connector.
7. Detach the vacuum hoses. EVAP Brake servo Delta Pressure Feedback Electronic System Sensor (DPFE) Exhaust gas recirculation (EGR) valve
8. Remove the nut and the oil level indicator tube.
9. Drain the coolant (shown from below).
10. Remove the coolant hoses from the thermostat housing.
11. Remove the coolant hose.
12. Drain off the fuel. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-207778) . Detach the fuel hose.
13. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
14. Disconnect the knock sensor (KS) and the oil pressure switch electrical connectors (shown from below). Oil pressure switch Knock sensor
15. Detach the intake manifold bracket. Loosen the nuts and remove the bolts.
16. Disconnect and remove the catalyst monitor sensor electrical connector.
17. Lower the vehicle.
18. Remove the heat shield. Power steering pipe Heat shield
19. Remove the catalytic converter from the exhaust manifold.
20. Remove the timing belt. For additional information, refer to «TIMING BELT»(ref-234425-S31821205612006060900000) .
21. Disconnect the crankshaft position sensor (CKP) electrical connector.
22. Disconnect the PCV and the fresh air hoses.
23. Remove the valve cover.
24. Loosen the cylinder head bolts in the indicated sequence.
25. Remove the cylinder head. Discard the gasket.

Scheme 808

Scheme 809

Scheme 810

Scheme 811

Scheme 812

Scheme 813

Scheme 814

Scheme 815

Scheme 816

Scheme 817

Scheme 818

Scheme 819

Scheme 820

Scheme 821

Scheme 822

Scheme 823

Scheme 824

Scheme 825

Scheme 826

1. Clean all gasket material from the mating surfaces on the cylinder head and cylinder block. Clean out the bolt holes in the cylinder block. Inspect the cylinder head for distortion. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-207747) .
2. Install a new head gasket on the cylinder block.
3. Install the cylinder head assembly and tighten the cylinder head bolts in the following sequence. Tighten all bolts in a single sequence to 50 Nm. Back the bolts off 1/2 turn. Tighten the bolts in sequence shown to 50 Nm. Rotate all the bolts in a single sequence an additional 180 degrees in two steps of 90 degrees each.
4. Install the valve cover.
5. Connect the fresh air and PCV hoses. Make sure that the twist-on PCV is secure.
6. Connect the crankshaft position sensor (CKP) electrical connector.
7. Install and tension the timing belt. For additional information, refer to «TIMING BELT»(ref-234425-S31821205612006060900000) .
8. Install the catalytic converter to the exhaust manifold.
9. Install the heat shield. Heat shield Power steering tube
10. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
11. Connect the knock sensor (KS) and the oil pressure switch electrical connector.
12. Connect the CMS sensor electrical connector.
13. Install the intake manifold bracket (shown with engine removed). Install the bolts and tighten the nuts.
14. Lower the vehicle.
15. Install the fuel hose.
16. Install the coolant hose.
17. Install the coolant hoses to the thermostat housing.
18. Install the oil level indicator tube.
19. Install the vacuum hose.
20. Install the vacuum hoses. EVAP Brake servo Delta Pressure Feedback Electronic System Sensor (DPFE) EGR-valve
21. Connect the HO2S electrical connector.
22. Connect both PCM connectors.
23. Install the speed control cable. Install the cable. Install the plastic clip.
24. Install the accelerator cable. Install the cable. Install the plastic clip.
25. Install the air cleaner housing. Connect the MAF electrical connector. Attach the intake hose. Install the air cleaner housing to the rubber bushing.
26. Change the engine oil (and the oil filter).
27. Fill the cooling system. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-207747) .
28. Connect the battery ground cable.
29. Install the battery. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-207791) .
30. Start the engine and check for leaks.

MATERIAL SPECIFICATIONS

Scheme 827

Scheme 828

Scheme 829

Scheme 830

Scheme 831

1. Remove the three-way catalytic converter (TWC). For additional information, refer to «EXHAUST SYSTEM»(ref-207777) .
2. Remove the bolts and the two brackets.
3. Remove the intake manifold bracket.
4. Remove the axleshaft bracket clamp.
5. Remove the axleshaft bracket.
6. Remove the coolant tube bolt.
7. Remove the oil pan drain plug and drain the engine oil. Install the drain plug.
8. Remove the oil pan. Discard the gasket.

Scheme 832

Scheme 833

Scheme 834

Scheme 835

Scheme 836

Scheme 837

1. Clean and inspect the mounting faces of both the oil pan and the cylinder block. To remove all traces of previous sealer, use solvent to clean the cylinder block and oil pan. Both surfaces must be flat, clean and dry.
2. Apply silicone gasket and sealant approximately 3.0 mm wide at the oil pump to cylinder block joints and the crankshaft rear oil seal retainer to cylinder block joints.
3. Install the oil pan gasket in the oil pan.
4. Install the oil pan. Tighten the bolts in the indicated sequence.
5. Install the two brackets and the bolts.
6. Install the coolant tube bolt.
7. Install the axleshaft bracket.
8. Install the axleshaft bracket clamp.
9. Install the intake manifold bracket.
10. Install the catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-207777) .
11. Fill the engine with engine oil
12. Start the engine and check for leaks.

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

Scheme 838

Scheme 839

Scheme 840

Scheme 841

Scheme 842

Scheme 843

Scheme 844

Scheme 845

Scheme 846

1. Remove the bolt and the camshaft position (CMP) sensor.
2. Disconnect the spark plug wires.
3. Remove the spark plugs.
4. Using the special tool remove the camshaft timing belt pulley.
5. Remove the intake manifold. Discard the gaskets.
6. Remove the exhaust manifold. Discard the gasket.
7. Remove the coolant outlet connection, thermostat and gasket.
8. Remove the ignition coil, ignition coil bracket and wires as one assembly.
9. Remove the rocker arms.
10. Remove the valve tappet(s). Remove the valve tappet guide plate retainers. Remove the valve tappet guide plates. Remove the valve tappets.
11. Remove the camshaft thrust plate.
12. Using the special tool, remove the camshaft front oil seal.
13. Remove the camshaft.
14. Using the special tool, compress the valve spring and remove the valve spring retainer key and the valve spring.
15. Slowly remove the special tool.
16. Remove the valves.
17. Remove and discard the valve stem seals.

Scheme 847

Scheme 848

Scheme 849

Scheme 850

Scheme 851

Scheme 852

Scheme 853

Scheme 854

Scheme 855

Scheme 856

1. Install the valve seals.
2. Install the exhaust and intake valves.
3. Using special tool, compress the valve spring and install the valve spring retainer.
4. Install the camshaft.
5. Apply a thin film of clean engine oil to the lip of the camshaft front seal.
6. Using the special tool, install the camshaft front seal.
7. Install the camshaft thrust plate.
8. Install the valve tappets into the cylinder head bores with the oil feed holes (1) in the valve tappets facing away from the oil feed holes (2) in the cylinder head bores.
9. Install the valve tappet guide plates (1) and valve tappet guide retainers (2).
10. Install the rocker arms.
11. Install the coil bracket, coil and spark plug wires.
12. Install the coolant outlet connection.
13. Install the exhaust manifold. Use a new gasket.
14. Install a new gasket and the intake manifold. Tighten the nuts and bolts to 10 Nm and 90 degrees.
15. Using the special tool. Install the camshaft timing belt pulley.
16. Install the spark plugs (shown with engine removed).
17. Push on the spark plug connector until it engages.
18. Install the CMP sensor.

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS