Ford Focus Service Manual: Engine - Manual Transaxle - Engine - 2.0L - Installation

	2,200# Floor Crane, Fold Away 300-OTC1819E or equivalent
	Lifting Bracket, Engine 303-050 (T70P-6000)
	Powertrain Lift 300-OTC1585AE or equivalent
	Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
	Adjustable Grip Arm, 1735A 014-00001 or equivalent

1. Using the Floor Crane and Spreader Bar, position the engine and transaxle together. Install the 7 bellhousing-to-engine fasteners.
   • Tighten to 48 Nm (35 lb-ft).

1. Using the Floor Crane, Engine Lifting Bracket and Spreader Bar, raise the engine and transaxle assembly onto the lift table.

1. Using the Powertrain Lift and Adjustable Grip Arm, secure the engine and transaxle assembly to the lift table.

1. Install the 7 new catalytic converter manifold studs.
   • Tighten to 17 Nm (150 lb-in).

1. Install the starter motor isolator.

1. Install the starter motor, stud bolt and the bolt.
   • Install the upper bolt and lower stud bolt finger-tight.
   • Tighten the upper bolt to 35 Nm (26 lb-ft).
   • Tighten the lower stud bolt to 35 Nm (26 lb-ft).

1. Position the 2 power steering tubes and the wiring harness as an assembly on the engine.

1. Install the engine ground wire and the bolt.
   • Tighten to 48 Nm (35 lb-ft).

1. Install the power steering tube bracket on the starter motor stud bolt and install the nut.
   • Tighten to 20 Nm (177 lb-in).

1. Attach the starter wire harness retainer to the starter motor stud bolt.

1. Connect the starter motor electrical terminals and install the 2 nuts.
   • Tighten the small nut to 5 Nm (44 lb-in).
   • Tighten the large nut to 12 Nm (106 lb-in).

1. Connect the Crankshaft Position (CKP) sensor electrical connector.

1. Attach the 2 CKP sensor wire harness retainers.

1. Connect the Power Steering Pressure (PSP) switch electrical connector.

1. Connect the A/C compressor electrical connector.

1. Connect the reversing lamp switch electrical connector.

1. Connect the Vehicle Speed Sensor (VSS) electrical connector.

1. Position the Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS) wire connector bracket and install the nut.
   • Tighten to 25 Nm (18 lb-ft).

1. Install the nut for the HO2S and CMS wire connector bracket.
   • Tighten to 25 Nm (18 lb-ft).

1. Using the lift table, position the engine and transaxle assembly in the vehicle.

1. Install the transaxle mount plate and the 5 nuts.
   • Tighten the center nut to 150 Nm (111 lb-ft).
   • Tighten the 4 outer nuts to 48 Nm (35 lb-ft).

1. Install the engine mount and the 2 bolts and the stud bolt.
   • Tighten to 48 Nm (35 lb-ft).

1. Install the 2 motor mount nuts.
   • Tighten to 90 Nm (66 lb-ft).

1. Install the 2 oil pan-to-bellhousing bolts.
   • Tighten to 48 Nm (35 lb-ft).

1. Install the 2 lower bellhousing-to-oil pan bolts.
   • Tighten to 48 Nm (35 lb-ft).

1. NOTE:

   The bolts are different lengths, make sure the bolts are in the correct location.

   Install the transaxle roll restrictor and the 2 bolts.

   1. Install the transaxle roll restrictor.
   1. Install the short bolt.
   1. Install the long bolt.
      • Tighten to 70 Nm (52 lb-ft).

1. Connect the throttle control electrical connector.

1. Connect the heater hose to the coolant tube.

1. Connect the upper radiator hose and the heater hose to the coolant bypass.

1. Install the power steering pump. For additional information, refer to Section  211-02.

1. Clean and inspect the catalytic converter flange. Refer to Exhaust Manifold Cleaning and Inspection in Section  303-00.

1. NOTICE: Failure to tighten the catalytic converter nuts to specification before installing the converter bracket bolts will cause the converter to develop an exhaust leak.

   NOTICE: Failure to tighten the catalytic converter nuts to specification a second time will cause the converter to develop an exhaust leak.

   Using a new gasket and 7 new nuts, install the catalytic converter and tighten in 2 stages in the sequence shown.
   • Stage 1: Tighten to 55 Nm (41 lb-ft).
   • Stage 2: Tighten to 55 Nm (41 lb-ft).

1. Install the heat shield and 6 bolts.
   • Tighten to 11 Nm (97 lb-in).

1. Install the catalytic converter support bracket and the 2 bolts.
   • Tighten to 22 Nm (16 lb-ft).

1. Install the 2 catalytic converter support bracket-to-engine bolts.
   • Tighten to 48 Nm (35 lb-ft).

1. NOTE:

   Clean the mating surfaces of the muffler assembly and catalytic converter.

   Using a new gasket and 2 new nuts, connect the flexpipe to the catalytic converter.

   • Tighten to 48 Nm (35 lb-ft).

1. Install 2 new O-ring seals and install the power steering tubes to the steering gear and install the bolt.
   • Tighten to 18 Nm (159 lb-in).

1. Install the power steering tube clip and the bolt.
   • Tighten to 10 Nm (89 lb-in).

1. Install the LH halfshaft. For additional information, refer to Section  205-04.

1. NOTE:

   Lubricate the engine oil filter gasket with clean engine oil prior to installing the oil filter.

   Install a new engine oil filter.

   • Tighten the oil filter three-fourths turn after the oil filter gasket makes contact with the oil filter adapter.

1. Connect the lower radiator hose to the radiator.

1. Install the cooling fan motor and shroud. For additional information, refer to Section  303-03.

1. Using 2 new O-ring seals, connect the A/C tubes to the A/C compressor.

1. Install the A/C tube bracket to the A/C compressor stud bolt and install the nut.
   • Tighten to 10 Nm (89 lb-in).

1. Install the 2 A/C tube nuts.
   • Tighten to 15 Nm (133 lb-in).

1. Position and attach the 4 B+ battery cable wire harness retainers (2 shown).

1. Install the generator. For additional information, refer to Section  414-00.

1. Install the accessory drive belt and tensioner. For additional information, refer to Section  303-05.

1. Install the splash shield and the retainers.

1. Install the 2 front wheels and tires. For additional information, refer to Section  204-04.

1. Install the radio capacitor ground cable and the bolt.
   • Tighten to 10 Nm (89 lb-in).

1. Install the engine oil level indicator.

1. Connect the hydraulic clutch line and grommet to the retaining bracket.

1. WARNING: Carefully
   read cautionary information on product label. For emergency medical information seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury.

   NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.

   Connect the clutch slave cylinder supply tube.
   • Install the clip.

1. NOTE:

   The shift cable abutment sleeve is colored white.

   NOTE:

   The selector cable abutment sleeve is colored black.

   Attach the transaxle cables to the bracket.
   1. Attach the shifter cable to the bracket, turning the abutment sleeves counterclockwise to open. Position the cables into the metal holders.
   1. Attach the selector cable to the bracket, turning the abutment sleeves counterclockwise to open. Position the cables into the metal holders.

1. Attach the gearshift cables.
   1. Attach the shifter cable to the shift mass.
   1. Attach the selector cable to the selector lever.

1. Adjust the gearshift cables. For additional information, refer to Section  308-00.

1. Connect the HO2S and CMS electrical connectors and attach the wire harness retainer.

1. Connect the starter wire harness electrical connector.

1. Connect the 3 PCM electrical connectors.

1. Attach the engine harness to the coolant outlet bracket harness retainer.

1. Connect and attach the 2 engine harness electrical connectors.

1. Attach the brake booster vacuum hose retainer.

1. Install the power brake booster vacuum tube into the quick connect fitting.

1. Position and connect the Evaporative Emission (EVAP) tube. For additional information, refer to Section  310-00.

1. Connect the fuel tube quick connect coupling to the fuel rail. For additional information, refer to Section  310-00.

1. Install the negative battery cable ground and the bolt.
   • Tighten to 6 Nm (53 lb-in).

1. Attach the 2 positive battery cable wire harness retainer.

1. Connect the positive battery cable nut.
   • Tighten to 10 Nm (89 lb-in).

1. Install the battery tray. For additional information, refer to Section  414-01.

1. Connect the crankcase vent tube to the valve cover.

1. Install the Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to Section  303-12.

1. Fill the engine with clean engine oil.

1. Fill and bleed the cooling system. For additional information, refer to Section  303-03.

1. Bleed the clutch system. For additional information, refer to Section  308-00.

1. Evacuate and charge the A/C system. For additional information, refer to Section  412-00.