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

Installation

1. Using the special tool install the crankshaft front oil seal. Coat the oil seal lip and crankshaft running surface with engine oil.
2. Install the crankshaft pulley hub. Install the timing belt thrust washer. Install the crankshaft pulley hub.
3. Install the timing belt. For additional information, refer to «TIMING BELT»(ref-234423-S39362823462006060900000) .

Removal

1. Remove the valve tappets.
2. Using special tools, remove the valve springs. Apply compressed air to the cylinders. Compress the valve springs and remove the valve collets. Remove the valve spring retainers and the valve springs and place them in order to one side. To remove the collets use some grease and a small screw driver.

1. Using special tools install the valve springs. Insert the valve springs and the valve spring retainers. Compress the valve springs and install the valve collets. Disconnect and remove the air supply.
2. Install the valve tappets.

1. Preparatory operations NOTE: Do not damage the mating faces. Clean the mating faces. NOTE: Mating faces must be free from oil and sealant residue. Clean all traces of oil residue and oil sludge from the oil pan.
2. Install 10 studs, M6 x 20, in the shown dead end bores.
3. Apply a 3 mm bead of sealant to the oil pan mating face.
4. Attach the oil pan and tighten the bolts in two stages. Fit the drain plug (shown with engine removed). Stage 1: 6 Nm Stage 2: 10 Nm
5. Install the catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-207777) .
6. Fill with engine oil. Fill capacity and engine oil according to specifications.

Vehicles with manual transaxle

Scheme 72

Scheme 73

1. Remove the clutch. For additional information, refer to «CLUTCH - IB5 TRANSAXLE»(ref-207766) , «CLUTCH - MTX75 TRANSAXLE»(ref-207767) or «CLUTCH - MT285 TRANSAXLE»(ref-207768) .
2. Remove the automatic transaxle. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION»(ref-207762) .
3. Using the special tool, remove the flywheel/drive plate.
4. Using the special tool, remove the oil seal.

All vehicles

Scheme 74

1. Using the special tool, install the oil seal. Install three flywheel bolts.
2. Using the special tool, install the flywheel/drive plate.
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 automatic transaxle. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION»(ref-207762) .

All Vehicles

Scheme 75

Scheme 76

Scheme 77

Scheme 78

Scheme 79

Scheme 80

Scheme 81

Scheme 82

Scheme 83

Scheme 84

Scheme 85

Scheme 86

Scheme 87

Scheme 88

Scheme 89

Scheme 90

Scheme 91

Scheme 92

Scheme 93

Scheme 94

Scheme 95

Scheme 96

Scheme 97

Scheme 98

Scheme 99

Scheme 100

Scheme 101

Scheme 102

Scheme 103

Scheme 104

Scheme 105

Scheme 106

Scheme 107

Scheme 108

Scheme 109

1. General remarks. The positions of the engine mounting and the engine roll restrictor are described looking from the transmission towards the engine. If necessary, use Special Tool 412-108 to remove coolant and ventilation hoses. Owing to special model variants, some job steps do not apply to all vehicles. These are clearly marked in the text. If necessary, separate the cable ties and renew on installation.
2. Release the fuel pressure. For additional information, refer to «FUEL SYSTEM PRESSURE RELEASE»(ref-207778-S01731693742005120100000) .
3. Open the coolant expansion tank.
4. Remove the battery tray and detach the ground cable. Unclip and separate the connector. Unclip the wiring harness. Unscrew the bolts. Detach the positive and negative cables.
5. Remove the air cleaner housing. Pull off the plug of the mass air flow (MAF) sensor. Detach the PCV hose. Detach the intake hose. Remove the air cleaner housing from the rubber bushing.
6. Detach the ground cable.
7. Remove the air cleaner intake with resonator.
8. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
9. Drain the coolant (shown from below). Install the drain plug after draining.
10. Drain the engine oil. Install the drain plug after draining.
11. Partially lower the vehicle.
12. Slacken the suspension strut nuts by five turns on both sides.
13. Remove both front wheels and tires. For additional information, refer to «WHEELS AND TIRES»(ref-234422) .
14. Lock the driver's gear shift lever using the special tool. Move the shift lever to neutral. Detach the shift lever cover and insert the special tool.
15. Detach the accelerator cable and the speed control cable (if equipped).
16. Pull off the connectors of the El coil and the radio interference filter.
17. Separate the heated oxygen sensor (HO2S) connector.
18. Disconnect the radiator fan plug. Separate the cable ties.
19. Disconnect the fuel injector wiring.
20. Disconnect the ground strap from the engine lifting eye.
21. Pull off the generator connector.
22. Detach the high-pressure pipe from the clutch slave cylinder. Pull out the clip. Pull out the high-pressure pipe and tie it up with cable ties.
23. Separate the harness connector.
24. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
25. Disconnect the plug of the vehicle speed sensor (VSS)
26. Disconnect the plug for the reversing lamp switch and the crankshaft position sensor (CKP sensor). Unclip the wiring loom from the engine.
27. Remove the air deflector and the radiator fan. Undo the clips on both sides (left side shown). Unhook the air deflector upwards and remove it downwards.
28. Partially lower the vehicle.
29. Pull off the low pressure hoses.
30. Detach the brake servo vacuum hose.
31. Detach the fuel pipes. Detach the ground cable.
32. Detach the coolant hoses.
33. Detach the shift cable and selector cable from the transmission. Detach the shift cable from the gear lever. Pretension the abutment collars by turning them in an anti-clockwise direction and remove the cable assembly from the bracket. Detach the selector cable from the selector lever. Pretension the abutment collars by turning them in an anti-clockwise direction and remove the cable assembly from the bracket. Undo the adjustment mechanism by pressing it in.
34. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
35. Remove the drive belt cover.
36. Disconnect the power steering pressure switch (PSPS), slacken the drive belt and remove it (vehicle without air conditioning shown). Turn the belt tensioner clockwise.
37. Detach the air conditioning compressor and tie it up on the radiator crossmember.
38. Detach the coolant hose and remove the power steering pump bolts.
39. Lower the vehicle.
40. Detach the coolant expansion tank and position it to one side.
41. Remove the PAS reservoir and position it to one side.
42. Detach the bracket of the power steering high-pressure pipe.
43. Detach the power steering pump and tie it up with cable ties.
44. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
45. Remove the flexible exhaust pipe.
46. Remove the engine roll restrictor.
47. Detach both suspension arms (left-hand side shown). Remove the bolt. Detach the lower arm ball joint.
48. Detach the right-hand front drive halfshaft with intermediate shaft. Detach the intermediate shaft bearing cap. Discard the nuts and bearing cap. Pull the intermediate shaft with front drive halfshaft from the transmission and tie up with cable ties. Close off the transmission with auxiliary plugs.
49. Detach the left-hand front drive halfshaft from the transmission using the special tool. Pull out the front drive halfshaft and tie up with cable ties. Close off the transmission with auxiliary plugs.
50. Put the assembly table with wooden blocks on it under the vehicle.
51. Carefully lower the vehicle until the engine and transmission assembly is positioned on the assembly stand.
52. Secure the engine and transmission assembly to the assembly stand with a retaining strap.
53. Remove the engine rear mounting.
54. Remove the engine front mounting.
55. Carefully raise the vehicle. Pull forwards the assembly stand with the engine and transmission assembly.
56. Hook the engine and transmission assembly into the crane.
57. Remove the starter motor and ground cable.
58. Remove the flange bolts.
59. Remove the flange bolts (continued).
60. Separate the engine from the transaxle.

All vehicles

Scheme 110

Scheme 111

Scheme 112

Scheme 113

Scheme 114

Scheme 115

Scheme 116

Scheme 117

Scheme 118

Scheme 119

Scheme 120

Scheme 121

Scheme 122

Scheme 123

Scheme 124

Scheme 125

Scheme 126

Scheme 127

Scheme 128

Scheme 129

Scheme 130

Scheme 131

Scheme 132

Scheme 133

Scheme 134

Scheme 135

Scheme 136

Scheme 137

Scheme 138

Scheme 139

Scheme 140

Scheme 141

Scheme 142

1. General remarks. The positions of the engine mounting and the engine roll restrictor are described looking from the transmission towards the engine. If necessary, use Special Tool 412-108 to remove coolant and ventilation hoses. Owing to special model variants, some steps do not apply to all vehicles. These are clearly marked in the text. If necessary, separate the cable ties and install new on installation.
2. Release the fuel pressure. For additional information, refer to «FUEL SYSTEM PRESSURE RELEASE»(ref-207778-S01731693742005120100000) .
3. Open the coolant expansion tank.
4. Remove the battery tray and detach the ground cable. Unclip and separate the connector. Unclip the wiring harness. Unscrew the bolts. Detach the positive and negative cables.
5. Remove the air cleaner housing. Detach the plug of the mass air flow (MAF) sensor. Detach the positive crankshaft ventilation (PCV) hose. Detach the intake hose. Remove the air cleaner housing from the rubber bushing.
6. Detach the ground cable.
7. Detach the ground cable from the battery terminal.
8. Remove the air cleaner intake with resonator.
9. Drain the coolant (shown from below). Screw the drain plug back in after draining.
10. Slacken the suspension strut nuts by five turns on both sides.
11. Detach the accelerator cable and the speed control cable (if equipped).
12. Detach the connectors of the El coil and the radio interference filter.
13. Detach the heated oxygen sensor (HO2S) connector.
14. Disconnect the radiator fan connector. Separate the cable ties (if necessary).
15. Disconnect the fuel injector wiring.
16. Remove the ground cable.
17. Detach the generator connector.
18. Disconnect the harness connector.
19. Remove the air deflector and the radiator fan. Undo the clips on both sides (left side shown). Unhook the air deflector upwards and remove it downwards.
20. Detach the vacuum hoses.
21. Detach the vacuum hoses.
22. Detach the brake servo vacuum hose.
23. Detach the fuel pipes.
24. Detach the coolant hoses.
25. Disconnect the selector lever cable from the automatic transaxle selector lever assembly.
26. Remove the oil filler pipe/selector cable bracket.
27. Detach the oil cooler pipes from the transaxle.
28. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
29. Drain the engine oil.
30. Remove the drive belt cover.
31. Disconnect the power steering pressure switch (PSPS), slacken the drive belt and remove it (vehicle without air conditioning shown). Turn the belt tensioner clockwise.
32. Detach the air conditioning compressor and tie it up on the radiator crossmember.
33. Detach the coolant hose and remove the bolts of the power steering pump.
34. Lower the vehicle.
35. Detach the bracket of the power steering high-pressure pipe.
36. Detach the power steering pump and position it to one side and secure with cable ties.
37. Remove both front wheels and tires. For additional information, refer to «WHEELS AND TIRES»(ref-234422) .
38. Remove the flexible exhaust pipe.
39. Remove the engine roll restrictor.
40. Detach both suspension arms (left-hand side shown). Remove the bolt. Detach the lower arm ball joint.
41. Detach the right-hand front drive halfshaft with intermediate shaft. Detach the intermediate shaft bearing cap. Discard the nuts and bearing cap. Pull the intermediate shaft with front drive halfshaft from the transmission and tie up with cable ties. Close off the transmission with auxiliary plugs.
42. Detach the left-hand front drive halfshaft from the transmission using the special tool. Pull out the front drive halfshaft and tie up with cable ties. Close off the transmission with auxiliary plugs.
43. Put the assembly table with wooden blocks on it under the vehicle.
44. Carefully lower the vehicle until the engine and transmission assembly is positioned on the assembly stand.
45. Secure the engine and transmission assembly to the assembly stand with a retaining strap.
46. Remove the engine rear mounting.
47. Remove the engine front mounting nuts (without coolant expansion tank shown).
48. Carefully raise the vehicle. Pull the assembly stand forwards with the engine and transmission assembly.
49. Hook the engine and transmission assembly into the crane.
50. Remove the starter motor and ground cable.
51. Remove the flange bolts.
52. Remove the flange bolts (continued).
53. Separate the engine from the transaxle.

All vehicles

Scheme 143

Scheme 144

Scheme 145

Scheme 146

Scheme 147

Scheme 148

Scheme 149

Scheme 150

Scheme 151

Scheme 152

Scheme 153

Scheme 154

Scheme 155

Scheme 156

Scheme 157

Scheme 158

Scheme 159

Scheme 160

Scheme 161

Scheme 162

Scheme 163

Scheme 164

Scheme 165

Scheme 166

Scheme 167

Scheme 168

Scheme 169

Scheme 170

Scheme 171

Scheme 172

Scheme 173

Scheme 174

Scheme 175

Scheme 176

Scheme 177

Scheme 178

Scheme 179

1. General note. If necessary, use Special Tool 412-108 to install coolant and ventilation hoses.
2. Preparatory operations Using a retaining strap, secure the transmission on the assembly stand. Hook the engine into the crane, bring into position at the transmission and support using wooden blocks.
3. Install the flange bolts.
4. Install the flange bolts. Detach the crane from the engine.
5. Install the starter motor and ground cable.
6. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
7. Position the engine and transmission assembly on the assembly stand below the vehicle. Carefully lower the vehicle.
8. Install the front engine mounting.
9. Install the rear engine mounting.
10. Remove the retaining strap from the transmission.
11. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) . Remove the assembly stand.
12. Install the engine roll restrictor.
13. Attach the right-hand input shaft with intermediate shaft.
14. Attach the left-hand drive shaft.
15. Attach both suspension lower arms (left-hand side shown). Attach the lower arm ball joint. Install the bolt.
16. Install the flexible exhaust pipe.
17. Lower the vehicle.
18. Tighten the rear engine mounting nuts/bolts.
19. Tighten the front engine mounting nuts.
20. Install the power steering pump and fit the upper bolts.
21. Attach the bracket to power steering high-pressure pipe.
22. Install the PAS reservoir.
23. Install the coolant expansion tank.
24. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
25. Attach the power steering pump lower bolts, power steering pump pressure switch electrical connector and the radiator lower coolant hose. Power steering pump lower bolts. Power steering pump pressure switch electrical connector. Radiator lower coolant hose.
26. Attach the air conditioning compressor.
27. Install and tension the drive belt and connect the power steering pressure switch (PSPS). Turn the belt tensioner clockwise.
28. Install the drive belt cover.
29. Install the front wheel.
30. Lower the vehicle.
31. Connect the cables to the transaxle and adjust them. Release the abutment bracket by turning it counterclockwise and install the cable in the bracket. Connect the shift cable from the gear selector lever. Release the abutment bracket by turning it counterclockwise and install the cable in the bracket. Connect the shift cable to the gearshift lever. Lock the adjusting mechanism by pressing down the clips.
32. Attach the coolant hoses (continued).
33. Attach the fuel pipes.
34. Attach the brake servo vacuum hose.
35. Attach the vacuum hoses.
36. Install the air deflector and the radiator fan. Hook the air deflector in place. Install the clips on both sides (left side shown).
37. Connect the plug for the reversing lamp switch and the crankshaft position sensor (CKP sensor). Clip on the wiring loom.
38. Connect the plug to the vehicle speed sensor (VSS)
39. Connect the harness connectors.
40. Attach the high-pressure pipe to the clutch slave cylinder. Slide on the clip.
41. Attach the generator connector.
42. Connect the fuel injector wiring.
43. Connect the radiator fan connector. Install the cable ties.
44. Attach the heated oxygen sensor (HO2S) connector.
45. Attach the connectors of the E1 coil and the radio interference filter.
46. Attach the accelerator cable and the speed control cable (if equipped).
47. Install the air cleaner intake with resonator.
48. Attach the ground cable.
49. Install the air cleaner housing. Press the air filter housing into the rubber bushings. Push on the mass air flow (MAF) sensor multiplug. Attach the PCV hose. Attach the intake hose.
50. Tighten the suspension strut nuts on the right and left. Tighten by hand with a ring spanner. Use a torque wrench to tighten to specification.
51. Install the battery tray. Attach the ground cable to the body. Attach the battery positive and negative cables. Install the bolts. Clip the wiring harness in place. Connect and clip in the plug.
52. Tighten the wheel nuts.
53. Remove the special tool 308-437.
54. Install and connect the battery. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-207791) .
55. Fill the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-207748-S36034059462005120100000) .
56. Fill manual transmission fluid.
57. Fill the engine with engine oil.
58. Check the routing of the vacuum hoses and wiring and secure them with cable ties.
59. Bleed the hydraulic clutch operating system. For additional information, refer to «CLUTCH SYSTEM BLEEDING»(ref-207765-S19193917342005120100000) .
60. Check the fluid levels after the road test and correct as necessary.
61. Check the engine and cooling system for leaks (visual inspection).

All vehicles

Scheme 180

Scheme 181

Scheme 182

Scheme 183

Scheme 184

Scheme 185

Scheme 186

Scheme 187

Scheme 188

Scheme 189

Scheme 190

Scheme 191

Scheme 192

Scheme 193

Scheme 194

Scheme 195

Scheme 196

Scheme 197

Scheme 198

Scheme 199

Scheme 200

Scheme 201

Scheme 202

Scheme 203

Scheme 204

Scheme 205

Scheme 206

Scheme 207

Scheme 208

Scheme 209

Scheme 210

Scheme 211

Scheme 212

Scheme 213

Scheme 214

Scheme 215

Scheme 216

1. General note. If necessary, use Special Tool 412-108 to install coolant and ventilation hoses.
2. Preparatory operations Using a retaining strap, secure the transmission on the assembly stand. Hook the engine into the crane, bring into position at the transmission and support using wooden blocks.
3. Install the flange bolts.
4. Install the flange bolts. Detach the crane from the engine.
5. Install the starter motor and ground cable.
6. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
7. Position the engine and transmission assembly on the assembly stand below the vehicle. Carefully lower the vehicle.
8. Install the engine front mounting.
9. Install the engine rear mounting.
10. Remove the retaining strap from the transmission.
11. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) . Remove the assembly stand.
12. Install the engine roll restrictor.
13. Attach the right-hand input shaft with intermediate shaft.
14. Attach the left-hand drive shaft.
15. Attach the both suspension lower arms (left-hand side shown). Attach the lower arm ball joint. Install the bolt.
16. Install the flexible exhaust pipe.
17. Lower the vehicle.
18. Tighten the engine rear mounting nuts/bolts.
19. Tighten the engine front mounting nuts.
20. Attach the power steering pump and install the upper bolts.
21. Attach the bracket to power steering high-pressure pipe.
22. Raise and support the vehicle. For additional information, refer to «JACKING AND LIFTING»(ref-234418) .
23. Attach the power steering pump lower bolts, power steering pressure switch electrical connector and the radiator lower coolant hose. Power steering pump lower bolts. Power steering pump pressure switch electrical connector. Radiator lower coolant hose.
24. Attach the air conditioning compressor.
25. Install and tension the drive belt and connect the power steering pressure switch (PSPS). Turn the belt tensioner clockwise.
26. Install the drive belt cover.
27. Install both front wheels and tires. For additional information, refer to «WHEELS AND TIRES»(ref-234422) .
28. Install the oil filler pipe/selector cable bracket.
29. Connect the selector lever cable to the automatic transaxle selector lever assembly.
30. Attach the oil cooler pipes to the transaxle.
31. Attach the coolant hoses (continued).
32. Attach the fuel pipes.
33. Attach the brake servo vacuum hose.
34. Attach the vacuum hoses.
35. Attach the vacuum hoses.
36. Install the air deflector and the radiator fan. Hook the air deflector in place. Install the clips on both sides (left side shown).
37. Connect the harness connectors.
38. Attach the generator connector.
39. Install the ground cable.
40. Connect the fuel injector cable ties.
41. Connect the radiator fan connector. Install the cable ties.
42. Attach the heated oxygen sensor (HO2S) connector.
43. Attach the connectors of the E1 coil and the radio interference filter.
44. Attach the accelerator cable and the speed control cable (if equipped).
45. Install the air cleaner intake with resonator.
46. Attach the ground cable.
47. Attach the ground cable to the battery terminal.
48. Install the air cleaner housing. Press the air filter housing into the rubber bushings. Push on the mass air flow (MAF) sensor multiplug. Attach the PCV hose. Attach the intake hose.
49. Tighten the suspension strut nuts on the right and left. Tighten by hand with a ring spanner. Use a torque wrench to tighten to specification.
50. Install the battery tray. Attach the ground cable to the body. Attach the battery positive and negative cables. Install the bolts. Clip the wiring harness in place. Connect and clip in the plug.
51. Install the battery.
52. Install and connect the battery. For additional information, refer to «BATTERY»(ref-207791-S37876352842005120100000) .
53. Fill the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-207748-S36034059462005120100000) .
54. Fill automatic transmission fluid. For additional information, refer to «GENERAL PROCEDURES»(ref-207762-S22767185292005120200000) .
55. Fill the engine with engine oil.
56. Check the routing of the vacuum hoses and wiring and secure them with cable ties.
57. Check the fluid levels after the road test and correct as necessary.
58. Check the engine and cooling system for leaks (visual inspection).