Removing the iB5 manual transmission 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)

General equipment:

Technological plugs
assembly table
Fixing clamp
Repair shop crane
wooden blocks

Withdrawal

All cars

1. General instructions:

The position of the engine mounts and engine roll limiters in the description corresponds to the view from the gearbox towards the engine.
If necessary, use special tool 303-397 to remove coolant and vent hoses.
Due to the different variants of one vehicle model, some operating steps are not applicable to all vehicles. In this case, this is clearly stated in the text.
If necessary, remove the clamps and replace them during installation.

2. Standard preparatory activities:

Note the radio key code.
Check the preset radio stations.

3. Drain the coolant. See Section 303-03 for more information.

4.

CAUTION: Disconnect the positive wire and ground wire from the battery. Remove the battery.

Remove the battery tray and disconnect the ground wire.

1.Release and disconnect the connector.
2.Remove the wiring harness.
3. Remove the screws.
4. Disconnect a positive wire and a wire of weight.

5. Remove the air filter housing.

1. Disconnect the plug connector of the mass air flow sensor (MAF).
2.Disconnect the PCV hose.
3.Disconnect the inlet hose.
Remove the air filter housing from the rubber bushing.

6. Disconnect the ground wire.

7. Remove the inlet pipeline.

NOTE: Lock against rotation with the Allen key.

Loosen the suspension strut nuts on both sides five turns.

9. Loosen the wheel nuts on the left and right front wheels.

10. Lock the shift lever using the special tool.

Shift the gearshift mechanism to neutral position.
Disconnect the shift lever cover and insert the special tool.

11. Disconnect the accelerator cable.

1.Unhook the rope.
2.Remove the plastic clip and set the accelerator cable aside.

12. Disconnect the EI coil and RFI filter connectors.

13. Disconnect the heated oxygen sensor connector (HO2S) and power steering pump pressure switch connector.

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

15. Disconnect the powertrain control module connector (RSM).

16. Disunite a socket of the generator.

17.

CAUTION: Brake fluid leakage. Observe precautions for handling brake fluid. See Section 206-00 for more information.

Disconnect the high pressure pipe from the clutch slave cylinder.

Release the clamp.
Disconnect the high pressure pipe and tie it with clamps.

18. Disconnect the engine wiring harness connector.

19. Disconnect the plug connector of the vehicle speed sensor (VSS).

20. Disconnect the plug connector of the reversing light switch and the crankshaft position sensor (TFR). Release the wiring harness from the clip on the engine.

21. 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.

22. Disconnect the low pressure hoses.

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

24.

WARNING: Fuel leakage. Observe fuel handling precautions.

Drain fuel. See Section 310-00 for more information.

Disconnect the fuel lines.
Disconnect the ground wire.

25. Disconnect the coolant hoses.

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

27. Disconnect the shift cable and gear selection cable. Disconnect the shift cable and the gear selection cable by unscrewing the support ring from the bracket. Turn out clockwise.

28. Remove the drive belt cover.

29. Loosen the tension of the drive belt and remove the belt (vehicles without air conditioning). Turn the belt tensioner clockwise.

Vehicles with air conditioning

30. Disconnect the air conditioning compressor and tie it to the radiator cross member.

All cars

31. Remove the power steering pump bolts and disconnect the coolant hose.

32. Lower the car.

33. Disconnect the expansion tank and set it aside.

34. Remove the PAS reservoir and set it aside.

35. Disconnect the power steering high pressure pipe bracket.

36. Disconnect the power steering pump and tie it with clamps.

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

38. Remove the flexible exhaust pipe.

39. Remove the engine roll limiter.

40. Disconnect both suspension arms (right side shown).

41. Disconnect both front wheels. See Section 204-04 for more information.

42.

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

Disconnect the right axle shaft of the front drive axle together with the intermediate shaft.

Disconnect the intermediate shaft bearing cap.
Discard nuts and bearing cap.
Remove the intermediate shaft with the axle shaft of the front drive axle from the gearbox and tie it with clamps.
Plug the holes in the gearbox with process plugs.

43.

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 axle shaft of the front drive axle from the gearbox and tie it. Plug the holes in the gearbox with process plugs.

44. Place an assembly stand with wooden blocks on it under the car.

45. Gently lower the car so that the engine assembly with the gearbox remains on the assembly stand.

46. Secure the engine assembly with the gearbox 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. Pull forward the assembly stand together with the engine and gearbox.

50. Hook the engine assembly with the gearbox to the crane.