Disassembling the engine (Power unit / Engine 1.6/1.8/2.0 Zetec-E / Ford Focus 1 1998-2004)

Special tool

	Hammer with movable striker 205-047 (15-011)
	Universal Flange Holding Wrench 205-072 (15030A)
	Support bracket 303-435-04 (21-064)
	Flywheel Locking Tool 303-254 (21-135)
	Engine Lifting Tool 303-122 (21-068A)
	Base plate 303-435-12 (21-150A)
	Oil pan puller 303-633 (21-227)
	Spark Plug Pliers 303-622 (21-226)

General equipment:

Wooden blocks
Fixing clamps
Lift

1. General remarks:

Until the assembly stand is connected, the engine remains suspended from the lift.
If the engine is mounted on an assembly stand and it is necessary to temporarily remove it from the lift, the engine should be secured using engine clamps.
If necessary, cut the clamps and replace them during installation.

2. Disconnect the catalytic converter bracket.

3. Remove the catalytic converter.

1.Remove the heat shield.
2. Remove the bolt from the catalytic converter bracket.

4. Remove the catalytic converter (continued).

5. Disconnect the oil pressure switch connector.

6. Disconnect the generator.

1. Disconnect the power cord.
2. Unscrew the bolt.
3. Release the bolt.

7. Disconnect the intake manifold. Remove seven bolts and two nuts.

8. Disconnect the additional elements located on the inlet side.

1.Generator support bracket.
2. Oil filter
3. Oil pressure relay

9. Secure the engine to the assembly stand.

1.Install the special tool.
2.Install the special tool.

10. Disconnect the additional elements located on the outlet side.

1.Bracket for power steering pump
2. Bracket for air conditioning compressor.

11. Disconnect the positive crankcase ventilation system.

12. Disconnect the timing belt cover.

1.Water pump pulley
2. Intermediate pulley of the drive belt
3. Timing Belt Center Cover/Front Engine Mount Bracket
4.Timing belt upper cover

NOTE: Lock the flywheel using special tool 303-254.

5. Disconnect the pulley/damper from the crankshaft.
6. Lower timing belt cover

13.

CAUTION: When disconnecting the spark plug connectors, do not pull on the wire. If necessary, disconnect the ignition wires from the ignition coil to prevent the cables from becoming kinked. Before disconnecting the spark plug connectors, twist them slightly to release the seals.

CAUTION: Disconnect each spark plug connector using only straight-line force in the direction of the spark plug axis (for angled spark plug connectors, use special tool 303-622).

Remove the cylinder head cover.

Disconnect the spark plug connectors.
1. Unscrew the bolts.
2. Remove the spark plugs.

14.

NOTE: Shown is the lower idler pulley design (produced prior to approximately 1/99).

NOTE: Crankshaft pulley and thrust washer installation position.

Disconnect the timing belt pulley and water pump.

1. Loosen the timing belt tensioner by turning it counterclockwise and disconnect.
2. Remove the timing belt.
3. Disconnect the upper idler pulley.
4. Disconnect the lower idler pulley.
5. Disconnect the water pump.
6. Remove the crankshaft pulley and thrust washer.

15.

NOTE: Design shown without lower idler pulley (produced from about 01/99 onwards).

NOTE: Crankshaft pulley and thrust washer installation position.

Disconnect the timing belt pulley and water pump.

1. Loosen the timing belt tensioner by turning it counterclockwise and disconnect.
2. Remove the timing belt.
3. Remove the intermediate pulley.
4. Disconnect the water pump.
5. Remove the crankshaft pulley and thrust washer.

16. Remove the pulleys from the camshafts. Use a special tool to prevent the pulleys from turning.

17.

NOTE: Loosen each bolt, working evenly in stages, in the sequence shown, loosening two turns per stage, and remove the bolts.

Remove the camshaft bearing caps.

Remove the oil seals.
Remove the camshafts.
Remove the valve lifters and set them aside one at a time.

18.

CAUTION: Mark bolts to be reused by marking them with one or two dots using a center punch. Bolts can be reused twice. Discard bolts if necessary.

CAUTION: Allow the cylinder head to cool to room temperature before performing the following steps.

NOTE: Follow the release sequence.

Remove the cylinder head bolts.

19. Raise the cylinder head. Attach the hoist to the engine lifting eyes, lift and remove the cylinder head and place it on a clean wooden block.

20. Disconnect the pressure and driven clutch discs.

21. Remove the flywheel. Disconnect the special tool.

22. Remove the drain plug and oil pan bolts.

23.

CAUTION: To avoid damaging the sealing surfaces, use only a tool specifically designed for this purpose to remove the oil pan. Do not use a chisel or screwdriver for removal.

Remove the oil pan. Attach the special tool, screw the lock nut into the oil pan until it stops and use several blows to separate the oil pan from the lower section of the crankcase.