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 lift tool 303-122 (21068A)
	Axle puller 308-237 (16-087)
	Radiator hose clamp remover and installer 303-397 (24-003)
	Gear Alignment Tool 307-350A (16-088)

General equipment:

Technological plugs
assembly table
Fixing clamp
Engine Crane
wooden blocks

All cars

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

2. Remove the battery tray. Refer to Section 414-01 for more information.

3. Remove the air filter housing.

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

4. Disconnect the headlight ground wire.

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

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

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

8. Remove the panel of finishing of the lever of a gear change.

Disconnect the plug connector of the traction control (in the presence of).
Disconnect the plug (s) seat heating (in the presence of).

NOTE: Make sure the shift mechanism is in neutral.

Using the special tool, lock the shift lever.

10. Disconnect the accelerator cable from the throttle body and position it to the side.

1.Disconnect cable.
2.Remove the clip.

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

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

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

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

15. Disconnect the electrical connection of the generator.

16.

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

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

17. Disconnect the plug connector of the engine wiring harness.

18. Remove the air deflector and radiator fan.

Release clips on both sides (left side shown).
Unhook the air deflector towards the top and remove it towards the bottom.

19. Disconnect the vacuum hoses from the throttle body.

20. Disconnect the vacuum hose of the vacuum brake booster.

21. Disconnect fuel lines and ground wire from manifold.

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

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

24. Disconnect the power steering line from the engine.

25. Turn out the top bolts of the pump of the amplifier of a steering.

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

27. Remove the front wheel and tire assembly. Refer to Section 204-04 for more information.

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

29. Open the shift and select cable cover.

30. Disconnect the shift and gear selection cables from the gearbox in the block with the drive axle. Disconnect the shift and select cables by turning the support sleeve clockwise.

31. Remove the accessory drive belt cover.

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

Vehicles with an air conditioning system.

33. Disconnect the air conditioning compressor from the engine and place it aside. Using zip ties, secure the air conditioning compressor to the cross member.

All cars

34. Remove the power steering pump. Using zip 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 pipe flexible connector can cause damage to the exhaust pipe leading to a malfunction.

CAUTION: Support the exhaust pipe flexible connector with a suitable bar.

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

38. Remove the engine mount.

39.

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

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

40.

CAUTION: The inner hinge must not be tilted more than 18 degrees. External hinge - at an angle exceeding 45 degrees.

Disconnect the right half shaft of the forward leading bridge and an intermediate shaft.

Disconnect the intermediate shaft bearing cap.
Discard the nuts and bearing cap as they are no longer needed.
Remove the countershaft and front axle shaft from the transaxle and secure them out of the way using zip ties.
Shut off the transaxle to prevent oil leakage or dirt ingress.

41.

CAUTION: The inner hinge must not be tilted more than 18 degrees. External hinge - at an angle exceeding 45 degrees.

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

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

43. Install the assembly stand and suitable wooden blocks under the car.

44. Gently lower the vehicle so that the engine/gearbox assembly sits on the assembly stand.

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

46. Fix the engine assembly with the gearbox in the block with the drive axle on the assembly stand using the fixing collar.

47. Remove the rear engine mount.

48. Remove the front engine mount.

49. Gently raise the car. Move forward the assembly stand with the engine mounted on it in assembly with the gearbox in the block with the drive axle.

50. Using the special tool, connect the engine/gearbox assembly to the engine valve.