Engine -- 2.0L Spi: Removal & Installation Ford Focus I рестайлинг

Removal

Vehicles with automatic transaxle

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1. Remove the transaxle. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION»(ref-207762) .
2. Remove the transaxle. For additional information, refer to «MANUAL TRANSAXLE/TRANSMISSION - IB5»(ref-207771) , «MANUAL TRANSAXLE/TRANSMISSION - MTX75»(ref-207772) or «MANUAL TRANSAXLE/TRANSMISSION - MT285»(ref-207773) .
3. Remove the clutch. For additional information, refer to «CLUTCH - IB5 TRANSAXLE»(ref-207766) , «CLUTCH - MTX75 TRANSAXLE»(ref-207767) or «CLUTCH - MT285 TRANSAXLE»(ref-207768) .
4. Remove the flywheel. Install the special tool. Remove the bolts.
5. Using the special tool, remove the crankshaft rear oil seal.
6. Inspect the crankshaft rear oil seal area for any damage which may cause the rear oil seal to leak. If necessary, repair or replace the crankshaft. For additional information, refer to «ENGINE»(ref-234425-S06610142572006060900000) in the Disassembly portion of this article or «ENGINE»(ref-234425-S25140234742006060900000) in the Assembly portion of this article.

Installation

All Vehicles

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1. Using the special tool, install the crankshaft rear oil seal. Lubricate the crankshaft surface and the sealing lip of the rear crankshaft oil seal with engine oil.
2. Install the flywheel. Tighten the bolts fingertight Install the special tool. Tighten the bolts.
3. Install the clutch. For additional information, refer to «CLUTCH - IB5 TRANSAXLE»(ref-207766) , «CLUTCH - MTX75 TRANSAXLE»(ref-207767) or «CLUTCH - MT285 TRANSAXLE»(ref-207768) .
4. Install the transaxle. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION»(ref-207762) .
5. Install the transaxle. For additional information, refer to «MANUAL TRANSAXLE/TRANSMISSION - IB5»(ref-207771) , «MANUAL TRANSAXLE/TRANSMISSION - MTX75»(ref-207772) or «MANUAL TRANSAXLE/TRANSMISSION - MT285»(ref-207773) .

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1. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-207778) .
2. Release the coolant system pressure.
3. Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-207791) .
4. Remove the air cleaner. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-207759) .
5. Detach the ground cable from the inner fender.
6. Remove the air cleaner intake tube and resonator.
7. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
8. Drain the coolant (shown from below). Allow the coolant to drain into a suitable container. Install the drain plug after draining.
9. Drain the engine oil. Allow the oil to drain into a suitable container. Install the drain plug after draining.
10. Partially lower the vehicle.
11. Loosen the strut and spring assembly upper mounting retaining nuts by five turns on both sides.
12. Remove the splash shield.
13. Detach the accelerator cable and the speed control cable (if equipped) from the throttle body.
14. Detach the intake manifold runner control (IMRC) actuator cable from the IMRC lever (intake manifold assembly shown removed for clarity). Rotate the IMRC lever. Detach the IMRC actuator cable from the intake manifold.
15. Remove the electronic ignition (El) coil cover.
16. Disconnect the block heater harness (if equipped).
17. Disconnect the starter field wire electrical connector.
18. Disconnect the fuel injector wiring harness.
19. Disconnect the ground cable from the engine lifting eye.
20. Disconnect the generator electrical connector.
21. Detach the hydraulic line from the clutch slave cylinder. Remove the clip. Remove the clutch line and secure it to one side using cable ties.
22. Disconnect the wiring harness electrical connector.
23. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
24. Disconnect the vehicle speed sensor (VSS) electrical connector.
25. Disconnect the reversing lamp switch electrical connector.
26. Partially lower the vehicle.
27. Disconnect the vacuum hoses from the intake manifold.
28. Detach the brake booster pipe from the intake manifold. Release the quick release coupling and detach the brake booster pipe.
29. Detach the fuel lines. Detach the ground cable.
30. Detach the coolant hoses.
31. Disconnect the oil cooler hose.
32. Detach the gearshift cables from the transaxle. Detach the gearshift cable and the selector cable from the selector levers. Detach the retaining bracket from the transaxle.
33. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
34. Remove the accessory drive belt.
35. Detach the air conditioning compressor and secure it to the radiator crossmember.
36. Remove the power steering pump lower retaining bolts and disconnect the radiator lower coolant hose from the water pump housing.
37. Disconnect the power steering pressure (PSP) switch electrical connector.
38. Disconnect the crankshaft position (CKP) sensor electrical connector.
39. Detach the coolant hose from the oil cooler.
40. Lower the vehicle.
41. Detach the coolant expansion tank and position it to one side.
42. Drain the power assisted steering (PAS) reservoir.
43. Detach the PAS reservoir and position it to one side.
44. Detach the power steering line bracket from the cylinder head.
45. Detach the power steering pump and bracket from the engine and position it to one side.
46. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
47. Remove the flexible exhaust pipe.
48. Remove the crossmember.
49. Detach the RH halfshaft and the intermediate shaft from the transaxle and secure it to one side. Allow the oil to drain into a suitable container. Discard the center bearing cap and locknuts.
50. Using the special tool, detach the LH halfshaft from the transaxle and secure it to one side. Allow the oil to drain into a suitable container. Discard the snap ring.
51. Position the assembly table with suitable wooden blocks under the engine and transmission assembly.
52. Carefully lower the vehicle until the engine and transmission assembly is positioned on the assembly stand.
53. Secure the engine and transmission assembly to the assembly stand with a retaining strap.
54. Remove the engine rear mount.
55. Remove the engine front mount.
56. Carefully raise the vehicle. Pull the assembly stand forward.
57. Using the special tools, secure the engine and transmission assembly to the hoist.
58. Remove the catalytic converter support bracket. Remove the catalyst monitor sensor.
59. Detach the catalytic converter from the exhaust manifold. Discard the gasket and nuts. Remove the heated oxygen (HO2S) sensor.
60. Remove the transaxle upper retaining bolts.
61. Disconnect the starter motor.
62. Remove the starter motor. Detach the ground cable from the transaxle.
63. Remove the transaxle RH retaining bolts.
64. Remove the transaxle LH retaining bolts.
65. Separate the engine from the transaxle.

All Vehicles

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1. Remove the hood. Disconnect the windshield washer hose and clips. Remove the four retainers (two each side) and remove the hood.
2. Disconnect the fuel line spring lock couplings. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-207778) .
3. Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-207791) .
4. Disconnect the crankcase breather hose.
5. Remove the air cleaner (ACL) housing. Disconnect the mass air flow (MAF) sensor electrical connector. Remove the intake hose. Remove the air cleaner housing from the rubber bushing.
6. Remove the air cleaner intake pipe.
7. Open the coolant expansion tank.
8. Drain the coolant (shown from below). Screw the drain plug back in after draining.
9. Remove the accelerator cable. Unhook the cable. Pull off the plastic clip and lay the accelerator cable to one side.
10. Remove the speed control cable (if equipped). Unhook the cable. Pull off the plastic clip and lay the accelerator cable to one side.
11. Disconnect the cable from the generator.
12. Disconnect the electrical connectors. Power steering pump pressure switch. Generator. Heated oxygen sensor (HO2S).
13. Disconnect both powertrain control module (PCM) connectors.
14. Detach the vacuum hoses. Evaporative emission (EVAP). Brake servo. Delta Pressure Feedback Electronic (DPFE) system sensor. EGR-valve and EGR vacuum regulator solenoid.
15. Detach the vacuum hose from the evaporative canister purge valve.
16. Remove the coolant expansion tank. For additional information, refer to «ENGINE COOLING»(ref-207748) .
17. Remove the PAS reservoir and lay it to one side.
18. Position aside the accessory drive belt. Rotate the tensioner clockwise and remove the belt from the power steering pulley.
19. Remove the power steering pump pulley.
20. Remove the power steering pump and position it to one side.
21. Detach the coolant hose from the intake manifold.
22. Detach the coolant hose from the water pump.
23. Detach the coolant hose from the thermostat housing.
24. Remove the upper starter motor bolts.
25. Disconnect the cooling fan motor electrical connectors.
26. Remove the pin-type retainers.
27. Remove the catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-207777) .
28. Disconnect the lower harness retainers.
29. Remove the cooling fan shroud. Release the top clips of the radiator to allow the cooling fan motor and shroud to be raised. Remove the fan and shroud.
30. Remove the drive belt cover.
31. Remove the drive belt.
32. Detach the air conditioning compressor and tie it up on the radiator crossmember.
33. Remove the generator (engine removed shown).
34. Detach the coolant hose from the coolant pipe.
35. Remove the coolant pipe bolt.
36. Remove the bolt and tube.
37. Remove the accessory drive bracket (engine removed shown).
38. Remove the transaxle lower flange bolts and catalytic converter bracket.
39. Remove the torque converter cover bolts.
40. Disconnect the torque converter from the engine drive plate (four nuts). Rotate the flywheel to access all bolts.
41. Remove nuts, bolts and bracket. Detach connector pin-type retainer.
42. Remove the retaining clip.
43. Remove the intermediate shaft bracket.
44. Disconnect the starter motor electrical connectors (two nuts).
45. Remove the starter motor. Remove the starter motor bolt.
46. Remove the crankshaft pulley. Remove the crankshaft pulley bolt.
47. Remove the left-hand transaxle flange bolts.
48. Remove the right-hand transaxle flange bolt.
49. Lower the vehicle.
50. Support the transaxle with a jack.
51. Install left and right side lifting brackets.
52. Using the special tool, install suitable floor crane. Raise the engine slightly to prevent pressure on the support insulators.
53. Remove the engine front mounting.
54. Disconnect the crankshaft position (CKP) sensor electrical connector.
55. Remove the upper transaxle flange bolts.
56. Separate the engine from the transaxle and remove it out the top.

SPECIAL TOOL SPECIFICATIONS Cylinder Ridge Reamer 303-016 (T64L-6011-EA) Strap Wrench 303-D055 (D85L-6000-A)

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1. Disconnect and remove the following. Vacuum hoses Coolant hoses and tubes Positive crankcase ventilation and fresh air hoses
2. Remove the clutch (if equipped). For additional information, refer to «CLUTCH - IB5 TRANSAXLE»(ref-207766) , «CLUTCH - MTX75 TRANSAXLE»(ref-207767) or «CLUTCH - MT285 TRANSAXLE»(ref-207768) .
3. Remove the flywheel. Install the special tool. Remove the bolts.
4. Attach the engine to stand.
5. Disconnect the exhaust gas recirculation tube from the EGR valve.
6. Disconnect the EGR tube from the exhaust manifold.
7. Remove the oil lever indicator tube.
8. Disconnect the crankshaft position (CKP) sensor electrical connector.
9. Disconnect the fuel injectors electrical connectors.
10. Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor electrical connectors.
11. Disconnect the oil pressure sender unit and the knock sensor.
12. Disconnect the fuel pressure sensor electrical connector.
13. Disconnect the electrical connectors. Camshaft position (CMP) sensor Intake manifold runner control (IMRC) Radio interference capacitor Ignition coil Water temperature indicator sender unit
14. Detach the retainers and remove the fuel charge wiring harness.
15. Remove the intake manifold bracket.
16. Remove the intake manifold and IMRC. Discard the gaskets.
17. Disconnect the spark plug wires.
18. Remove the ignition coil, ignition coil bracket and wires as one assembly.
19. Remove the oil filter.
20. Remove the knock sensor.
21. Remove the oil pressure sender unit.
22. Remove the CKP sensor.
23. Remove the generator.
24. Remove the accessory drive belt bracket.
25. Remove the exhaust manifold. Discard the gasket.
26. Remove the water outlet connection, thermostat and gasket.
27. Remove the spark plugs.
28. Remove the crankshaft pulley.
29. Remove the timing belt cover.
30. Remove the upper timing belt cover.
31. Align the timing marks.
32. Remove the timing belt. Use an 8 mm Allen key and turn counterclockwise one-fourth turn. Insert a 3 mm (1/8 inch) drill bit to lock the timing belt tensioner in place. Remove the timing belt.
33. Remove the timing belt tensioner. Remove the bolt. Remove the tensioner.
34. Remove the water pump. Discard the gasket.
35. Remove the crankshaft sprocket and the timing belt guide.
36. Remove the valve cover.
37. Remove the cylinder head. Discard the gasket.
38. Remove the oil pan. Discard the gasket.
39. Remove the oil pump screen cover and tube. Discard the gasket.
40. Remove the oil baffle.
41. Remove the oil pump. Discard the gasket.
42. Remove and discard the oil pump seal.
43. Remove the crankshaft rear seal retainer. Discard the gasket.
44. Remove the four connection rod caps.
45. Install a short length of rubber tubing over the connection rod bolts to avoid damage to the crankcase journals.
46. Inspect the top of each cylinder bore before removing the piston. If a ridge has formed at the top of the cylinder, the ridge must be removed before the pistons can be removed. Remove the ridge as follows: Turn the crankshaft clockwise until the piston is at the bottom of its cylinder bore. Place a clean ship cloth over the piston head to collect cuttings. Using the special tool 303-016 (T64L-6011-EA), remove the ridge. Never cut into the ring travel area more than 0.8 mm (1/32 in) when removing the ridge.
47. Remove the pistons and the connecting rod assemblies.
48. Remove the five main bearing caps and the lower crankshaft main bearings.
49. Remove the crankshaft.
50. Remove the bearings. Upper crankshaft main bearings. Crankshaft thrust main bearing.

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1. Install the transaxle.
2. Install the transaxle LH retaining bolts.
3. Install the transaxle RH retaining bolts.
4. Install the starter motor. Attach the ground cable to the transaxle.
5. Connect the starter motor electrical connectors.
6. Install the transaxle upper retaining bolts.
7. Attach the catalytic converter to the exhaust manifold. Install the heated oxygen (HO2S) sensor.
8. Install the catalytic converter bracket. Install the catalytic monitor sensor.
9. Using a retaining strap, secure the engine and transmission assembly on the assembly stand. Remove the special tools.
10. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
11. Position the engine and transmission assembly under the vehicle. Carefully lower the vehicle.
12. Install the engine front mount.
13. Install the engine rear mount.
14. Remove the retaining strap from the engine and transmission assembly, and remove the assembly stand.
15. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
16. Attach the RH halfshaft and the intermediate shaft to the transaxle. Install the center bearing cap.
17. Attach the LH halfshaft to the transaxle.
18. Install the crossmember.
19. Install the flexible exhaust pipe.
20. Lower the vehicle.
21. Tighten the engine rear mount nuts and bolts.
22. Tighten the engine front mount nuts.
23. Attach the power steering pump and the bracket to the engine.
24. Attach the power steering line bracket to the cylinder head.
25. Install the power assisted steering (PAS) reservoir.
26. Install the coolant expansion tank.
27. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
28. Connect the power steering pressure (PSP) switch electrical connector.
29. Connect the crankshaft position (CKP) sensor electrical connector.
30. Connect the radiator lower coolant hose to the coolant pump housing.
31. Connect the radiator lower coolant hose to the oil cooler.
32. Attach the air conditioning compressor.
33. Install the accessory drive belt.
34. Lower the vehicle.
35. Connect the oil cooler hose.
36. Attach the gearshift cables to the transaxle. Attach the retaining bracket to the transaxle. Attach the gearshift cable and the selector cable to the selector levers.
37. Connect the starter field wire electrical connector.
38. Attach the coolant hoses to the thermostat housing.
39. Attach the fuel pipes to the fuel rail.
40. Attach the brake servo vacuum hose to the intake manifold.
41. Attach the vacuum hoses to the throttle body.
42. Connect the reversing lamp switch electrical connector. Clip on the wiring loom.
43. Connect the vehicle speed sensor (VSS) electrical connector.
44. Connect the wiring harness connectors.
45. Attach the clutch supply line to the clutch slave cylinder. Install the clip.
46. Connect the generator electrical connector.
47. Connect the fuel injector wiring harness.
48. Install the electronic ignition (El) coil cover.
49. Attach the accelerator cable and the speed control cable (if equipped) to the throttle body.
50. Install the splash shield.
51. Connect the engine block heater (if equipped).
52. Connect the intake manifold runner control (IRMC). Rotate the IMRC lever. Connect the IMRC actuator cable.
53. Install the air cleaner intake tube and resonator.
54. Tighten the strut and spring assembly upper mounting retaining nuts.
55. Attach the ground cable to the inner fender.
56. Install the air cleaner. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-207759) .
57. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-207791) .
58. Install and connect the battery. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-207791) .
59. Fill the cooling system. For additional information, refer to «ENGINE COOLING»(ref-207748) .
60. Fill the transaxle.
61. Fill the engine with engine oil.
62. Bleed the hydraulic clutch operating system. For additional information, refer to «CLUTCH CONTROLS - IB5 TRANSAXLE»(ref-207769) .
63. Fill and bleed the PAS system. For additional information, refer to «POWER STEERING»(ref-207743) .

All Vehicles

Note. The location of the engine mountings and the engine support insulators are given looking from the automatic transaxle to the engine.

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1. Support the transaxle with a jack.
2. Using the special tool and a suitable floor crane to bring the engine into installation position and lower it.
3. Install the transaxle upper flange bolts.
4. Connect the crankshaft position (CKP) sensor electrical connector.
5. Install the engine front mount. Remove the engine crane and floor jack.
6. Remove left and right side lifting brackets.
7. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
8. Install the transaxle right-hand flange bolt.
9. Install the transaxle left-hand flange bolts.
10. Install the crankshaft pulley. Tighten the crankshaft pulley bolt.
11. Install the starter motor.
12. Install the starter motor electrical connectors.
13. Install the intermediate shaft bracket.
14. Install the retaining clamp.
15. Attach the intake manifold bracket. Install the bolts and tighten the nuts.
16. Install the torque converter to the engine drive plate (four nuts). Rotate flywheel to install nuts.
17. Install the torque converter cover.
18. Install the transaxle lower flange bolts.
19. Install the accessory drive bracket.
20. Position back tube and install bolt.
21. Install the coolant pipe bolt.
22. Connect the coolant hose to the coolant tube.
23. Install the generator (engine removed shown).
24. Install the compressor.
25. Position back drive belt.
26. Install fan shroud.
27. Attach the harness retainers.
28. Position and support the catalytic converter.
29. Loosely install the lower clamp.
30. Remove the support from the catalytic converter.
31. Lower the vehicle.
32. Install the catalytic converter to the manifold. Use a new gasket and nuts.
33. Install the heat shield.
34. Install the upper starter bolts.
35. Install the power steering pump.
36. Using the special tool to prevent the power steering pump pulley from rotating install the power steering pump nut. Install the power steering pump pulley.
37. Install the accessory drive belt. Turn the belt tensioner clockwise.
38. Install the coolant hoses to the water pump.
39. Install the coolant hose to the intake manifold.
40. Connect the coolant hoses to the coolant hose connector.
41. Push the power steering fluid reservoir into place.
42. Connect the vacuum hose to the evaporative canister purge valve.
43. Connect the vacuum hoses. Evaporative emission (EVAP). Brake servo. Delta pressure feedback electronic (DPFE). Exhaust gas recirculation (EGR) valve and EGR vacuum regulator solenoid.
44. Install the fan to the radiator. Install the fan wiring harness.
45. Connect the radiator fan electrical connector.
46. Connect both powertrain control module (PCM) connectors.
47. Connect the electrical connectors. Power steering pump pressure switch. Generator. Heated oxygen sensor (HO2S).
48. Connect the cable to the generator.
49. Install the speed control cable (if equipped). Hook the cable in place. Clip on the plastic clip.
50. Install the accelerator cable. Hook the cable in place. Clip on the plastic clip.
51. Connect the fuel line spring lock coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(ref-207778) .
52. Install the intake pipe.
53. Install the air cleaner (ACL) housing. Connect the MAF sensor electrical connector. Install the outlet pipe.
54. Attach the crankcase breather hose.
55. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
56. Install the accessory drive belt cover.
57. Connect the catalytic converter to the flexible pipe. Use a new gasket and nuts.
58. Install the bracket. Tighten the bolts.
59. Tighten the bracket adjusting bolts.
60. Install the catalyst monitor sensor.
61. Install the catalyst monitor sensor electrical connector.
62. Lower the vehicle.
63. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-207791) .
64. Fill the engine with engine oil.
65. Install the coolant expansion tank. For additional information, refer to «ENGINE COOLING»(ref-207748) .
66. Install the hood. Position the hood and install the four bolts (two each side). Install the windshield washer hose and clips.