2002 Ford Focus S2FACTORY OEM SERVICE PROCEDURE

Section 1618 (Engine): Removal: Engine: Removal

WARNING: This page is about a different car, the 2006 Mercury Montego, 2006 Ford Freestyle, and 2006 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.
WARNING:
  1. Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury.
  2. Fuel in the fuel system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard.

    All vehicles 

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM PRESSURE RELEASE .
  3. Disconnect the negative and positive battery cables. For additional information, refer to REMOVAL AND INSTALLATION .
  4. Recover the A/C system. For additional information, refer to REFRIGERANT SYSTEM RECOVERY .
  5. Remove the air cleaner outlet pipe and air cleaner. For additional information, refer to REMOVAL AND INSTALLATION .
  6. Remove the cowl vent panel. For additional information, refer to REMOVAL AND INSTALLATION .
  7. Drain the cooling system. For additional information, refer to DRAINING .
  8. Remove the LH and RH halfshafts. For additional information, refer to REMOVAL and REMOVAL .
  9. Remove the exhaust flex pipe and LH catalytic converter. For additional information, refer to REMOVAL AND INSTALLATION .
  10. Remove and discard the roll restrictor cross brace-to-roll restrictor bolt.
    Fig 1: Locating Upper Roll Restrictor Bolt
    G03989188Courtesy of FORD MOTOR CO.
  11. Remove and discard the 4 roll restrictor cross brace bolts and the cross brace.
    Fig 2: Identifying Transaxle Roll Restrictor Bar Bolts
    G03989189Courtesy of FORD MOTOR CO.
  12. Remove the bolt and detach the ground strap from the RH fender.
    Fig 3: Locating Fender Bolt
    G04655745Courtesy of FORD MOTOR CO.
  13. Disconnect the redundant clip, press the quick release coupling button and disconnect the fuel tube from the fuel rail.
    Fig 4: Locating Quick Release Coupling Button
    G04655746Courtesy of FORD MOTOR CO.
  14. Detach the fuel tube clip from the upper intake manifold.
    Fig 5: Locating Fuel Tube Clip
    G04655747Courtesy of FORD MOTOR CO.
  15. Disconnect the vapor tube from the purge valve.
    Fig 6: Locating Vapor Tube
    G03990216Courtesy of FORD MOTOR CO.
  16. Disconnect the 2 powertrain control module (PCM) electrical connectors and detach the wiring conduit.
    Fig 7: Locating Powertrain Control Module (PCM) Electrical Connectors
    G04655749Courtesy of FORD MOTOR CO.
  17. Disconnect the power steering reservoir hose and detach the retainer.
    Fig 8: Locating Power Steering Reservoir Hose Retainer
    G04655750Courtesy of FORD MOTOR CO.
  18. Remove the bolt and detach the ground wire from the LH fender.
    Fig 9: Locating Fender Bolt
    G04655751Courtesy of FORD MOTOR CO.
  19. Remove the nut and detach the B+ terminal from the battery cable.
    Fig 10: Locating Battery Cable Nut
    G04655752Courtesy of FORD MOTOR CO.

    20. Vehicles with CVT transaxle 

  20. Disconnect the shift cable.
    Fig 11: Locating Shift Cable End
    G03990221Courtesy of FORD MOTOR CO.
  21. Disconnect the 16-pin electrical connector and detach the wiring retainers.
    • Detach the electrical connector from the shift cable bracket.
    Fig 12: Locating Electrical Connector From Shift Cable Bracket
    G04655754Courtesy of FORD MOTOR CO.
  22. Remove the 2 bolts and position the shift cable aside.
    Fig 13: Locating Shift Cable Bracket Bolts
    G03990223Courtesy of FORD MOTOR CO.

    23. Vehicles with 6-speed transaxle 

  23. Disconnect the shift cable.
    Fig 14: Locating Shift Cable End
    G03991743Courtesy of FORD MOTOR CO.
  24. Disconnect the 16-pin electrical connector and detach the wiring retainer.
    • Disconnect the electrical connector from the shift cable bracket.
    Fig 15: Locating Electrical Connector From Shift Cable Bracket
    G04655757Courtesy of FORD MOTOR CO.
  25. Remove the 3 shift cable bracket bolts and position the cable and bracket aside.
    Fig 16: Locating Shift Cable Bracket Bolts
    G04655758Courtesy of FORD MOTOR CO.

    26. All vehicles 

  26. Disconnect the heater hose and the positive crankcase ventilation (PCV) coolant hose.
    Fig 17: Locating Positive Crankcase Ventilation (PCV) Coolant Hose
    G04655759Courtesy of FORD MOTOR CO.
  27. Disconnect the brake booster vacuum hose from the upper intake manifold.
    Fig 18: Locating Brake Booster Vacuum Hose
    G04655760Courtesy of FORD MOTOR CO.
  28. Disconnect the coolant hoses from the thermostat housing.
    Fig 19: Locating Coolant Hoses From Thermostat Housing
    G04655761Courtesy of FORD MOTOR CO.
  29. Detach the coolant tube retainers.
    Fig 20: Locating Coolant Tube Retainers
    G04655762Courtesy of FORD MOTOR CO.
  30. Disconnect the 10-pin electrical connector and detach the wiring retainers.
    Fig 21: Locating 10-Pin Electrical Connector
    G04655763Courtesy of FORD MOTOR CO.
  31. Disconnect the A/C high-pressure switch electrical connector.
    Fig 22: Locating A/C High-Pressure Switch Electrical Connector
    G04655764Courtesy of FORD MOTOR CO.
  32. Remove the bolt and disconnect the A/C compressor manifold tube assembly.
    Fig 23: Locating A/C Compressor Manifold Tube Assembly Bolt
    G04655765Courtesy of FORD MOTOR CO.
  33. Remove the nut and position the A/C tubes aside.
    Fig 24: Locating A/C Tubes Nut
    G04655766Courtesy of FORD MOTOR CO.
  34. Disconnect the transmission cooler hoses.
    Fig 25: Locating Transmission Cooler Hoses
    G04655767Courtesy of FORD MOTOR CO.
  35. Disconnect the power steering cooler hose.
    Fig 26: Locating Power Steering Cooler Hose
    G04655768Courtesy of FORD MOTOR CO.
  36. Remove the engine oil pan drain plug and drain the engine oil.
    • Install the plug and tighten to 26 N.m (19 lb-ft).
    Fig 27: Locating Engine Oil Pan Drain Plug
    G04655769Courtesy of FORD MOTOR CO.
  37. If equipped, disconnect the block heater electrical connector and detach the wiring harness.
    Fig 28: Locating Block Heater Electrical Connector
    G03990550Courtesy of FORD MOTOR CO.
  38. Remove the 2 pin-type retainers and the torque converter lower access plug.
    Fig 29: Locating Torque Converter Lower Access Plug
    G04655771Courtesy of FORD MOTOR CO.
  39. Remove and discard the 4 torque converter nuts.
    Fig 30: Locating Torque Converter Nuts
    G04655772Courtesy of FORD MOTOR CO.
  40. Remove the 3 engine-to-transaxle bolts and the LH catalytic converter bracket.
    Fig 31: Locating Transaxle-To-Engine Bolts
    G03990545Courtesy of FORD MOTOR CO.
  41. If equipped, remove the 2 driveshaft support bracket bolts.
    Fig 32: Identifying Driveshaft Cross Brace Mounting Bolts
    G03990728Courtesy of FORD MOTOR CO.
  42. If equipped, remove the bolts and disconnect the driveshaft.
    • Position the driveshaft aside.
    Fig 33: Locating Driveshaft Bolts
    G04655775Courtesy of FORD MOTOR CO.
  43. Using the special tool, lower the powertrain and subframe from the vehicle.
    Fig 34: Lowering Powertrain & Subframe From Vehicle Using Special Tool
    G04655776Courtesy of FORD MOTOR CO.
  44. Remove the nuts and separate the stabilizer bar links from the struts.
    Fig 35: Identifying Stabilizer Bar Link Nuts
    G03990245Courtesy of FORD MOTOR CO.
  45. Remove the nuts and separate the outer tie rods from the wheel knuckles.
    • Discard the nuts.
    Fig 36: Locating Outer Tie Rods From Wheel Knuckles Nuts
    G04655778Courtesy of FORD MOTOR CO.
  46. Remove and discard the steering column intermediate shaft bolt.
    • Detach the intermediate shaft from the steering gear.
    Fig 37: Locating Intermediate Shaft Bolt
    G04655779Courtesy of FORD MOTOR CO.
  47. Using the special tool, support the powertrain and the subframe.
    Fig 38: Supporting Powertrain & Subframe Using Special Tool
    G04655780Courtesy of FORD MOTOR CO.
  48. Remove the 6 bolts and the 2 rear subframe brackets.
    Fig 39: Locating Rear Subframe Brackets Bolts
    G04655781Courtesy of FORD MOTOR CO.
  49. Remove the 2 forward subframe bolts and washers.
    Fig 40: Locating Subframe Bolts & Washers
    G04655782Courtesy of FORD MOTOR CO.
  50. Remove the power steering pressure (PSP) tube bracket bolt and disconnect the PSP switch electrical connector.
    Fig 41: Locating Power Steering Pressure (PSP) Tube Bracket Bolt
    G04655783Courtesy of FORD MOTOR CO.
  51. Remove the bolt and disconnect the power steering fluid tubes.
    Fig 42: Locating Power Steering Fluid Tubes Bolt
    G04655784Courtesy of FORD MOTOR CO.
  52. Disconnect the RH catalyst monitor sensor electrical connector and detach the pin-type retainers from the subframe.
    Fig 43: Locating Catalyst Monitor Sensor Electrical Connector
    G04655785Courtesy of FORD MOTOR CO.

    53. Vehicles with CVT transaxle 

  53. Disconnect the transaxle bulkhead electrical connector.
    Fig 44: Locating Transaxle Bulkhead Electrical Connector
    G03990860Courtesy of FORD MOTOR CO.
  54. Detach the wiring harness retainer from the transaxle.
    Fig 45: Locating Wiring Harness Retainer From Transaxle
    G04655787Courtesy of FORD MOTOR CO.
  55. Detach the wiring harness retainers from the transaxle.
    Fig 46: Locating Wire Harness Retainers At Transaxle
    G03990911Courtesy of FORD MOTOR CO.
  56. Detach the lower wiring harness retainers from the transaxle.
    Fig 47: Locating Lower Wiring Harness Retainers From Transaxle
    G04655789Courtesy of FORD MOTOR CO.
  57. Remove the 4 bolts and the roll restrictor bracket.
    Fig 48: Locating Roll Restrictor Bracket Bolts
    G04655790Courtesy of FORD MOTOR CO.
  58. Detach the wiring harness from the roll restrictor.
    Fig 49: Locating Wiring Harness At Roll Restrictor Bolts
    G03990915Courtesy of FORD MOTOR CO.
  59. Remove the 2 bolts and the roll restrictor.
    Fig 50: Locating Roll Restrictor Bolts
    G04655792Courtesy of FORD MOTOR CO.
  60. Remove the starter motor electrical connector cover.
    Fig 51: Identifying Electrical Cover For Starter Motor Electrical Connectors
    G03990919Courtesy of FORD MOTOR CO.
  61. Remove the nuts and disconnect the starter motor wiring.
    Fig 52: Identifying Starter Motor Electrical Connectors
    G03990920Courtesy of FORD MOTOR CO.
  62. Remove the 2 bolts and the starter motor.
    Fig 53: Identifying Starter Motor Mounting Bolts
    G03990263Courtesy of FORD MOTOR CO.
  63. Remove the bolt and disconnect the ground cable.
    Fig 54: Locating Ground Wire
    G03991001Courtesy of FORD MOTOR CO.

    64. Vehicles with 6-speed transaxle 

  64. Disconnect the wire harness from the transmission control unit (TCU).
    Fig 55: Identifying Transmission Control Module Electrical Connector
    G03991767Courtesy of FORD MOTOR CO.
  65. Remove the 4 bolts and the roll restrictor bracket.
    Fig 56: Locating Roll Restrictor Bracket Bolts
    G04655798Courtesy of FORD MOTOR CO.
  66. Remove the 2 bolts and the roll restrictor.
    Fig 57: Locating Roll Restrictor Bolts
    G04655799Courtesy of FORD MOTOR CO.
  67. Remove the starter motor electrical connector cover.
    Fig 58: Locating Starter Motor Electrical Connector Cover
    G04655800Courtesy of FORD MOTOR CO.
  68. Remove the nuts and disconnect the starter motor wiring.
    Fig 59: Locating Starter Motor Wiring Nuts
    G04655801Courtesy of FORD MOTOR CO.
  69. Remove the 2 bolts and the starter motor.
    Fig 60: Locating Starter Motor Bolts
    G04655802Courtesy of FORD MOTOR CO.
  70. Remove the bolt and disconnect the ground cable.
    Fig 61: Locating Ground Cable Bolt
    G04655803Courtesy of FORD MOTOR CO.

    71. All vehicles 

  71. Install the special tool to the RH cylinder head.
    Fig 62: View Of Special Tool On RH Cylinder Head
    G03990013Courtesy of FORD MOTOR CO.
  72. Install the special tool to the LH cylinder head.
    Fig 63: Special Tool Installed Onto LH Cylinder Head
    G03990012Courtesy of FORD MOTOR CO.
    73. NOTE: When installing the lower half of the lifting bracket it will be easier to loosely install the upper bolt first then install the lower bolt.
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.