Removing the engine with a manual transmission (Power unit / Engine 1.4/1.6 Zetec-SE / Ford Focus 1 1998-2004)

Special tool

	Engine lift tool 303-122 (21068A)
	Coolant hose clamp remover/installer 303-397 (24-003)
	308-256 (16-089) 308-237 (16-087)

General equipment:

transmission fluid
assembly table
Fixing clamp
Repair shop crane

Withdrawal

All cars

NOTE: If necessary, use special tool 303-397 to remove coolant and vent hoses.

NOTE: The location of the engine mounts in the description is based on looking away from the gearbox towards the engine.

WARNING: Risk of scalding when the engine is warm.

Open the expansion tank of the cooling system.

2. Relieve pressure in the fuel supply system. Refer to Section 310-00 for more information.

3. Loosen the nuts on the upper supports of the right and left suspension struts three turns.

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

5. Remove battery. Refer to Section 414-01 for more information.

6. Remove the battery shelf.

1.Release and disconnect the connector.
2.Remove the screws.
3.Release the wiring harness.

7. Remove the air filter along with the air intake hose.

1. Air intake hose.
2. Disconnect the plug connector of the mass air flow sensor (MAF).
Disconnect the crankcase ventilation hose from the cylinder head.

8. Remove the inlet pipeline.

9. Disconnect the accelerator cable.

1.Release the clip.
2.Unscrew the cable from the bracket.

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

11. Remove the engine ground cable and exhaust manifold heat shield.

1. Engine ground cable
2.Exhaust manifold heat shield (three bolts)

12. Remove the exhaust manifold (shown from below). Remove the gasket.

13. Disconnect the plug connector.

1.Ignition coil (EI)
2.Condenser

14. Disunite the plug connector of the engine wiring harness. Release the shift cables.

15. Disconnect the heater hose.

16. Disconnect the hoses.

1.Disconnect the fuel pressure regulator vacuum hose.
2. Disconnect the vacuum hose of the vacuum brake booster.

Vehicles without air conditioning

17. Disunite the plug connector and disconnect the wire.

1. Disconnect the electrical wiring from the generator
2.Plug connector for power steering pump

Vehicles with air conditioning

18. Disconnect the electrical wiring from the generator.

All cars

19. Release the power steering reservoir and set it aside.

20. Remove the coolant and heater hoses.

1.Hose of the expansion tank of the cooling system.
2.Heater hose
3. Coolant hose.

21. Disconnect the carbon filter vacuum line.

22. Disconnect the coolant hose.

23. Disconnect the pipeline from the clutch master cylinder. Shut off the line and set it aside.

24. Raise the car. See Section 100-02 for more information.

25. Remove the drive belt cover.

26. Loosen the tension and remove the drive belt.

Vehicles without air conditioning

27. Disconnect the power steering hydraulic line bracket.

28. Disconnect the power steering pump along with the base plate. Tie using zip ties.

Vehicles with air conditioning

29. Disconnect the power steering high pressure pipe bracket.

30. Disconnect the air conditioning compressor. Tie using zip ties.

All cars

31. Disconnect the shift cable and gear selection cable.

32. Disconnect the starter ground cable.

33. Disconnect the lower suspension arms on both sides.

34. Disconnect the clip from the intermediate bearing of the right front axle shaft. Discard clamps and nuts as they are no longer needed.

35.

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

Remove the right front axle shaft from the gearbox and tie it down. Plug the holes in the gearbox with process plugs.

36.

CAUTION: The inner hinge must not be tilted more than 18 degrees and the outer hinge must not be tilted more than 45 degrees.

Remove the left front axle shaft from the gearbox and tie it down. Plug the holes in the gearbox with process plugs.

Vehicles with air conditioning

37. Disconnect the bracket and power steering pump along with the drive belt tensioner. Tie using zip ties.

All cars

38.

NOTE: The roll limiter is under tension.

Remove the roll limiter.

39. Disconnect the heated oxygen sensor connector (HO2S).

40. Disconnect the plug connector of the oil pressure switch.

41. Disconnect the plug connector of the crankshaft position sensor (TFR sensor).

42.

CAUTION: If the flexible pipe is bent too much, it may cause damage which will lead to failure of the element.

Secure the flexible exhaust pipe with a support sleeve or suitable rail.

43. Disconnect a reception exhaust pipe.

Remove the gasket.
Remove the exhaust manifold.

44. Preparatory work before removing the engine / gearbox:

Place an assembly stand under the engine and gearbox.
Lower the vehicle just enough so that the engine/gearbox assembly remains on the assembly stand.
Support the engine on wooden blocks and secure it to the assembly stand using the fixing clamps.

45. Disconnect the fuel lines. See Section 310-00 for more information.

46. Disconnect the front engine mount.

47. Remove the rear engine mount.

Loosen and remove the center nut.
Loosen and remove the engine mount nuts.

48. Raise the vehicle. Refer to Section 100-02 for more information. Pull the engine and transmission forward and out from under the vehicle.

49. Bring the crane and, using a special tool, pick up the engine to it.

50. Position the engine and gearbox so that only the gearbox rests on the assembly stand. Support the gearbox with wooden blocks and secure it with a clamp.

51. Disconnect the engine wiring harness. Disconnect the vehicle speed sensor connector (VSS).