Turbocharged 1.8L Diesel with Fuel Injection (Focus 1)

Removal

1. Disconnect the ground cable from the battery. For additional information, refer to Section 414-01.

2. Remove the air cleaner. Refer to Section 303-12 for additional information.

3. Remove the top engine cover.



4. Disconnect the positive crankcase ventilation (PCV) hose from the valve cover.



5. Remove the air cleaner outlet pipe.

• 1. Slide the clamp to release the pipe.
• 2. Remove the pipeline.

6. Disconnect the charge air cooler inlet pipe.

• 1. Release the clamp.
• 2. Unscrew the nut.

7. Remove the charge air cooler inlet pipe.



8. Disconnect the exhaust gas recirculation (EGR) line. Remove the two bolts.



9. Remove the bolts securing the EGR cooler to the exhaust manifold and remove the EGR cooler. Discard the gasket as it is no longer needed.



10. Disconnect the vacuum line of the vacuum diaphragm unit.





11. Remove the EGR pipe.

12. Remove the catalytic converter. Refer to Section 309-00 for additional information.

13. Remove the engine roll limiter bolt. Move the engine as far forward as possible.



14. Disconnect the EGR cooler and secure it to the side.



15. Disconnect the supply and return oil lines.

• 1. Disconnect the oil feed line. Discard the sealing washers as they are no longer needed.
• 2. Disconnect the oil return line. Discard the O-ring as it is no longer needed.

16. Remove the return oil line from the cylinder block.





17. Lower the vehicle.

18. Remove the upper exhaust manifold mounting bolts.



19. Raise and support the vehicle. Refer to Section 100-02 for additional information.

20. Remove the catalytic converter support bracket from the cylinder block.



21. Disconnect the turbocharger assembly from the exhaust manifold. Discard the gasket as it is no longer needed.





22. Remove the turbocharger assembly with the exhaust manifold.

• 1. Move the engine as far forward as possible.
• 2. Remove the turbocharger.

Installation

NOTE: Install a new exhaust manifold gasket.

NOTE: Install a new oil return line O-ring.

NOTE: Install new oil feed line sealing washers.

1. Install the exhaust manifold assembly with the turbocharger.

• 1. Move the engine as far forward as possible.
• 2. Install the turbocharger.

2. Install the lower exhaust manifold mounting bolts.





3. Install the catalytic converter support bracket.



4. Lower the vehicle.

5. Install the upper exhaust manifold mounting nuts and bolts.



6. Connect the vacuum line of the vacuum diaphragm unit.



7. Raise and support the vehicle. Refer to Section 100-02 for additional information.



8. Connect the return oil line to the cylinder block.



9. Install the feed and return oil lines.

Note: Install a new O-ring.

• 1. Install the return oil line.

NOTE: Install new sealing washers.

• 2. Install the oil supply line.

10.

NOTE: Do not tighten the bolts at this stage.

Install the EGR cooler mounting bolts (finger tighten and then loosen 1.5 turns).



11. Lower the vehicle.



12.

NOTE: Do not tighten the bolts at this stage.

Install the EGR pipe (hand tighten the EGR pipe to EGR valve mounting bolts).



13. Connect the EGR cooler to the exhaust manifold. Install a new gasket between the EGR cooler and the exhaust manifold.



14. Raise and support the vehicle. Refer to Section 100-02 for additional information.

15. Tighten the EGR cooler mounting bolts to the cylinder block.



16. Install the engine roll limiter bolt.



17. Install the catalytic converter. Refer to Section 309-00 for additional information.

18. Tighten the EGR pipe mounting bolts to the EGR valve.



19. Connect the charge air cooler inlet pipe.



20.

CAUTION: Make sure that the inside of the charge air cooler intake pipe is clean and free of oil, as this will impair the bond between the pipe and the charge air cooler. Failure to follow this instruction may result in engine damage.

Install the charge air cooler inlet pipe.

• 1. Tighten the clamp.
• 2. Tighten the nut.

21. Install the air cleaner outlet pipe.

• 1. Install the pipeline.
• 2. Slide the clamp to bring the pipeline to the required position.

22. Connect the PCV hose to the valve cover.



23. Install the top engine cover.



24. Install the air cleaner. Refer to Section 303-12 for additional information.

25. Connect the ground cable to the battery. For additional information, refer to Section 414-01.

(The original can be found on the specified resource: fordbook)