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

Special tool

	Engine Lifting Tool 303-122 (21068A)
	Axle puller 308-237 (16-087)
	Radiator Hose Clamp Remover and Installer 303-397 (24-003)
	Gearshift Alignment Tool 307-350A (16-088)

General equipment:

Technological plugs
Assembly table
Fixing clamp
Engine lifting crane
Wooden blocks

All cars

1. Relieve fuel system pressure. Refer to Section 310-00 for additional information.

2. Remove the battery tray. For more information, refer to Section 414-01.

3. Remove the air filter housing.

1. Disconnect the mass air flow (MAF) sensor connector.
2. Disconnect the breather pipe from the air filter.
3. Disconnect the air cleaner outlet pipe from the throttle body.
Remove the air filter housing from the rubber grommets.

4. Disconnect the headlight ground wire.

5. Loosen the upper strut assembly mounting nuts with the spring by five turns on both sides (left side shown).

6. Disconnect the gear shift boot from the floor console.

7. Disconnect the shift lever trim panel from the floor console. Disconnect the clips.

8. Remove the gear shift lever trim panel.

Disconnect the traction control connector (if equipped).
Disconnect the seat heating plug(s) (if equipped).

NOTE: Make sure the gear shift mechanism is in neutral position.

Using the special tool, lock the gear shift lever.

10. Disconnect the accelerator cable from the throttle body and place it aside.

1. Disconnect the cable.
2. Disconnect the clamp.

11. Disconnect the plug connectors of the EI coil and the radio interference suppression filter.

12. Disconnect the power steering pressure (PSP) switch connector.

13. Disconnect the radiator fan connector. Remove the clamps.

14. Disconnect the powertrain control module (PCM) connector.

15. Disconnect the electrical connection of the generator.

16.

CAUTION: If brake fluid comes into contact with the paintwork, the affected area should be immediately washed with cold water.

Disconnect the clutch slave cylinder feed line and place it aside. Disconnect the spring clip.

17. Disconnect the engine wiring harness plug connector.

18. Remove the air deflector and radiator fan.

Release the clamps on both sides (left side shown).
Unhook the air deflector with an upward movement and remove it with a downward movement.

19. Disconnect the vacuum hoses from the throttle body.

20. Disconnect the brake booster vacuum hose.

21. Disconnect the fuel lines and ground wire from the manifold.

22. Disconnect the expansion tank of the cooling system from the wheel arch and place it to the side.

23. Disconnect the power steering fluid reservoir and place it aside.

24. Disconnect the power steering line from the engine.

25. Remove the upper power steering pump bolts.

26. Drain the coolant. Refer to Section 303-03 for additional information.

27. Remove the front wheels and tires. For additional information, refer to Section 204-04.

28. Disconnect the electrical connectors of the reverse light switch, crankshaft position (CKP) sensor and heated oxygen sensor (H02S). Disconnect the wiring harness from the engine.

29. Open the shift and selector cable cover.

30. Disconnect the shift and selector cables from the transaxle. Disconnect the shift and selector cables by turning the support sleeve clockwise.

31. Remove the accessory drive belt cover.

32. Remove the accessory drive belt (vehicle without air conditioning system shown). Turn the belt tensioner clockwise.

Cars with air conditioning system.

33. Disconnect the air conditioning compressor from the engine and place it aside. Using cable ties, secure the air conditioning compressor to the crossmember.

All cars

34. Remove the power steering pump. Using cable ties, secure the power steering pump to the crossmember.

35. Disconnect the coolant pump hose. Allow the coolant to drain into a suitable container.

36. Lower the car.

37.

CAUTION: Excessive bending of the exhaust flexible pipe may cause damage to the flexible pipe, leading to malfunction.

CAUTION: Support the exhaust pipe flexible connector using a suitable tire.

Remove the flexible insert of the exhaust system. Discard the gaskets and nuts as they are no longer needed.

38. Remove the engine support mount.

39.

CAUTION: To prevent damage to the ball joint seal, cover it with a soft cloth.

Disconnect the lower arm ball joint from the steering knuckle (both sides). Remove the heat shield.

40.

CAUTION: The inner hinge must not be deflected at an angle exceeding 18 degrees. The outer hinge must not be deflected at an angle exceeding 45 degrees.

Disconnect the right half shaft of the front drive axle and the intermediate shaft.

Remove the intermediate shaft bearing cap.
Discard the nuts and bearing cap as they are no longer needed.
Remove the intermediate shaft and front drive axle shaft from the transaxle and secure them to the side using clamps.
Shut off the transaxle to prevent oil leakage or dirt from entering.

41.

CAUTION: The inner hinge must not be deflected at an angle exceeding 18 degrees. The outer hinge must not be deflected at an angle exceeding 45 degrees.

Remove the left front drive axle shaft from the transaxle and secure it to the side. Shut off the transaxle to prevent oil leakage or dirt from entering.

42. Disconnect the vehicle speed sensor (VSS) connector.

43. Place the assembly stand and suitable wooden blocks under the vehicle.

44. Carefully lower the vehicle so that the engine assembly with the gearbox in the block with the drive axle is positioned on the assembly stand.

45. Disconnect the coolant hoses from the engine. Allow the coolant to drain into a suitable container.

46. Secure the engine assembly with the gearbox in the block with the drive axle on the assembly stand using a fixing clamp.

47. Remove the rear engine mount.

48. Remove the front engine mount.

49. Carefully lift the vehicle. Move forward the assembly stand with the engine mounted on it, assembled with the gearbox in the block with the drive axle.

50. Using the special tool, connect the engine assembly with the gearbox in the block with the drive axle to the engine crane.