SM 3

2002 Ford Focus LX
2002 ENGINE Engine - 2.0L Zetec-E (Zetec) - Focus
2002 ENGINE
Engine - 2.0L Zetec-E (Zetec) - Focus
SPECIFICATIONS
ENGINE DATA
ENGINE 2.0L ZETEC-E (ZETEC) GENERAL DATA SPECIFICATION

Engine management EEC V/SEFI
Emission standard 96 EEC
Fuel 91 RON unleaded
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Identification code CAA
Firing order 1-3-4-2
Bore 84.8 mm
Stroke 88.0 mm
Cubic capacity 1,988 cm3
Compression ratio 9.6:1
Maximum engine performance at 5,300 RPM 130 hp
Maximum engine torque at 4,000 RPM 130 lb ft
Idle speed RPM 800 RPM
Speed limitation (rev/min) 7,100 RPM
ENGINE OIL
ENGINE 2.0L ZETEC-E (ZETEC) ENGINE OIL SPECIFICATIONS

Viscosity/ambient
Description Specification
temperature
Recommended engine oils - -
SAE 5W -20 Engine Oil certified for
SAE 5W -20 / below -30°C ILSAC GF-3 and
gasoline engines by the American
to over +40°C WSS-M2C153-H
Petroleum Institute
SAE 5W -20 / below -30°C ACEA A1/B1 and
Ford Formula E Economy Engine Oil
to over +40°C WSS-M2C914-A
If engine oils of this specification are not available, engine oils of specification API SH/EC,
ACEA A2/B2 or ACEA A3/B3 may also be used.
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2002 Ford Focus LX
CAPACITIES
ENGINE 2.0L ZETEC-E (ZETEC) ENGINE OIL CAPACITIES SPECIFICATIONS

Litres
Engine oil, initial fill including filter 4.35
Engine oil, oil change including filter 4.25
Engine oil, oil change excluding filter 3.75
LUBRICANTS, FLUIDS, SEALERS AND ADHESIVES
ENGINE 2.0L ZETEC-E (ZETEC) LUBRICANTS, FLUID, SEALERS AND

ADHESIVES SPECIFICATIONS
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Item Specification
Sealant, camshaft bearing caps WSK-M2G348-A5
Sealant, cylinder block mating faces (Hylosil 502) WSK-M4G320-A
Sealant, cylinder block mating faces (Loctite Ultrablack) WSE-M4G320-A2
(alternative)
Sealant, crankshaft position sensor ESW-1C155-A
Sealant, crankshaft position sensor (alternative) WSD-M1C-226-A
Sealant, oil pan WSE-M4G323-A6
Thread locking compound SDM-M4G9107-A
Spark plug thread lubricant (Never Seeze) WSD-M13P8-A1
Lubricant, injection nozzle O-rings WSEM-2C903-A1
Silicone grease for spark plug connector seal A696-M1C171-AA
High-temperature grease for clutch disc engagement splines ESD-M1C220-A
CYLINDER BLOCK
ENGINE 2.0L ZETEC-E (ZETEC) CYLINDER BLOCK SPECIFICATIONS

Description mm
Cylinder bore diameter, class 1. 84.800 - 84.810
Inner diameter, main bearing shells installed 58.011 - 58.038
Inner diameter, main bearing shells installed (main bearing shells with 58.008 - 58.031
stepped sizes)
Main bearing radial clearance 0.011 - 0.058
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Main bearing radial clearance (main bearing shells with stepped sizes) 0.020 - 0.042
Main bearing parent bore 62.287 - 62.300
PISTONS
ENGINE 2.0L ZETEC-E (ZETEC) PISTONS SPECIFICATIONS

Description mm
Piston diameter, class 1. 84.770 - 84.780
Piston clearance in cylinder 0.010 - 0.030
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Piston ring gaps (installed)
0.30 - 0.50
- upper compression ring
- lower compression ring 0.30 - 0.50
- oil scraper ring 0.40 - 1.40
Ring gap position: The piston ring gaps must be distributed evenly around the circumference of
the piston This also applies to the oil scraper ring elements. Align the ring gaps at 120 degrees to
each other.
CRANKSHAFT
ENGINE 2.0L ZETEC-E (ZETEC) CRANKSHAFT SPECIFICATIONS

Description mm
Main bearing journal diameter 57.980-58.000
Main bearing journal end float 0.09-0.26
Connecting rod bearing journal diameter 46.89-46.91
LOWER CRANKSHAFT SPACER
ENGINE 2.0L ZETEC-E (ZETEC) LOWER CRANKSHAFT SPACER

SPECIFICATIONS
Description mm
Required spacer washer thickness if there is a gap between -
the cylinder block and the lower crankcase of:
0.26 mm - 0.50 mm 0.25
0.51 mm - 0.75 mm 0.50
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CONNECTING ROD
ENGINE 2.0L ZETEC-E (ZETEC) CONNECTING ROD SPECIFICATIONS

Description mm
Big end bore diameter 49.89 - 49.91
Small end bore diameter 19.951 - 19.981
Inner diameter, connecting rod bearing shells installed 46.926 - 46.960
Radial connecting rod bearing clearance 0.016 - 0.070
Axial connecting rod bearing clearance 0.090 - 0.320
PISTON PIN
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ENGINE 2.0L ZETEC-E (ZETEC) PISTON PIN SPECIFICATIONS
Description mm
Piston pin length 55.800 - 56.200
Piston pin diameter, white 19.997 - 20.000
Piston pin diameter, red 20.625 - 20.628
Piston pin clearance in piston 0.016 - 0.049
CAMSHAFT
ENGINE 2.0L ZETEC-E (ZETEC) CAMSHAFT SPECIFICATIONS

Description mm
Bearing journal diameter 25.960 - 25.980
Camshaft bearing radial clearance 0.020 - 0.070
Camshaft end float 0.080 - 0.220
Lobe lift intake 8.90
Lobe lift exhaust 8.70
Theoretical valve maximum lift intake 8.90
Theoretical valve maximum lift exhaust 8.70
VALVES
ENGINE 2.0L ZETEC-E (ZETEC) VALVES SPECIFICATIONS

Description mm
Valve clearance in the valve guide
Intake valve 0.017-0.064
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Exhaust valve 0.017-0.064

Intake valve clearance (at 20°C ° 5°C) 0.11-0.18
Exhaust valve clearance (at 20 °C ° 5°C) 0.27-0.34
CYLINDER HEAD
ENGINE 2.0L ZETEC-E (ZETEC) CYLINDER HEAD SPECIFICATIONS

Description Specification
Maximum distortion (mating surface) 0.1 mm
Height of mating surface 1.76 mm - 2.12 mm
Peak-to-valley height of mating surface (reference length 2.5 mm R3z = 6.0 "MU"m
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vertical to groove direction)
Oil pressure at 800 - 850 RPM 1.3 bar - 2.5 bar
Oil pressure at 4000 RPM 3.7 bar - 5.5 bar
TORQUE SPECIFICATIONS
ENGINE 2.0L ZETEC-E (ZETEC) TORQUE SPECIFICATIONS

Description N.m lb-ft lb-in
Hose clamps 4 - 35
Intake manifold studs 5 - 44
Intake manifold bolts and nuts 18 13 -
EGR tube assembly to EGR valve 40 30 -
EGR pipe to ignition coil bracket 6 - 53
EGR tube assembly to catalyst 40 30 -
Heat shield to exhaust manifold 10 - 89
Exhaust manifold studs 5 - 44
Exhaust manifold nuts 16 12 -
Catalytic converter to exhaust manifold 48 35 -
Catalytic converter to exhaust 47 35 -
Right-hand driveshaft center bearing 25 18 -
Generator to bracket 25 18 -
Generator bracket to upper cylinder block bolts 25 18 -
Generator bracket to lower cylinder block bolts 65 48 -
Transmission flange bolts 47 35 -
Starter motor to transmission 35 26 -
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Oil drain plug, MTX transmission 45 33 -

Oil control plug, MTX transmission 45 33 -
Flywheel bolts 112 83 -
Clutch pressure plate 29 21 -
Engine roll restrictor to transmission 48 35 -
Engine roll restrictor to subframe 48 35 -
Engine rear mount to body 48 35 -
Engine rear mount (nut on transmission mounting bracket) 133 98 -
Engine front mount to engine 80 59 -
Engine front mount to body 48 35 -
Power steering pump to bracket 24 18 -
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Power steering pump bracket 48 35 -
Cylinder head bolts (1) - -
Camshaft bearing cap bolts (1) - -
Cylinder head cover (1) - -
Spark plugs 15 11 -
Timing belt tensioner 25 18 -
Camshaft timing belt pulleys 68 50 -
Upper timing belt cover 10 - 89
Ignition coil (EI) bracket to cylinder head 21 15 -
Thermostat housing 20 15 -
Fuel rail 10 - 89
Engine rear lifting eye 16 12 -
Engine rear lifting eye studs 6 - 53
Engine front lifting eye 47 35 -
Cylinder block - - -
Engine oil drain plug 25 18 -
Oil pressure switch 27 20 -
Cylinder block oil gallery blanking plugs 23 17 -
Heater pipe bracket to oil pan 10 - 89
Oil pan to lower crankcase (1) - -
Lower crankcase to cylinder block 22 16 -
Oil pump 11 8 -
Oil intake pipe to oil pump 10 - 89
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Main bearing bolts (1) - -

Connecting rod bearing cap bolts (1) - -
Coolant pump 18 13 -
Crankshaft rear oil seal carrier 20 15 -
Drive belt idler pulley 40 30 -
Crankcase ventilation pipe bracket 23 17 -
Crankcase ventilation 10 - 89
Coolant pump pulley 24 18 -
Crankshaft belt pulley 115 85 -
Crankshaft position sensor bracket 21 15 -
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Crankshaft position sensor to bracket 8 - 71
Idler pulley 23 17 -
Knock sensor 20 15 -
(1) Refer to the procedure in this article.
DESCRIPTION AND OPERATION

ENGINE
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Fig. 1: Identifying 2.0L Zetec-E Engine
Courtesy of FORD MOTOR CO.
The vehicle range is fitted with the "New Generation 2.0L Zetec-E engine". The most significant
features are:
Hydraulic engine mountings

16 valve DOHC
Full flow oil filter
Aluminum alloy cylinder head
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Cast iron block

High temperature resistant coating on exhaust valves
Valve train with mechanical tappets
Modified timing belt guide
Aluminum timing belt cover with integral engine mounting function to reduce noise,
vibration and harshness (NVH)
Aluminum crankcase reinforcement and flat oil pan to reduce NVH
Generator with check-back function for generator load
The changes made are:
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close coupled tri-metal catalytic converter
EGR system
Adjustable valve tappets
use of a cylinder head temperature (CHT) sensor in place of an engine coolant temperature
(ECT) sensor.
VIN Derivative location on the cylinder block
Fig. 2: Identifying VIN Derivative Location On Cylinder Block

Zetec-E Engine Design
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Central timing belt cover/front engine mounting bracket
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Fig. 3: Identifying Central Timing Belt Cover/Front Engine Mounting Bracket
The new timing belt cover is further reinforced by a vertical support. The central timing belt
cover and the front engine mounting have to be removed to fit a new timing belt.
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Cylinder Head
Valve Train
The exhaust valve springs are marked blue whilst the inlet valve springs are marked red. The
valve clearance can be adjusted by exchanging the valve tappets. Precision is required when
adjusting the valve clearance in order to avoid repeated removal and reinstallation of the
camshafts.
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Fig. 4: Identifying Engine Valve Train Components

Mechanical bucket tappet
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The level of wear is so minimal that initial checking and adjustment of the valve clearance is not
necessary until 150,000 km (90,000 miles).
Drive belt
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Fig. 5: Identifying Engine Drive Belt Components
A new timing belt must be installed after 150,000 km (90,000 miles) or after 10 years.
A new timing belt must always be installed after repair work in which it was removed.
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Timing Belt Tensioner
CAUTION: Only tension the timing belt by turning in a counterclockwise

direction.
An automatic timing belt tensioner ensures that the belt has the correct tension. When a new belt
is fitted, the tensioner is moved into the base setting (arrowhead (3) and marker (2) are in line).
This base setting is taken up by one of the cams (4). Another (spring-loaded) cam ensures that the
belt is kept at the correct tension when the engine is running. The belt tensioner moves up to 30
degrees from its center position in each direction.
NOTE: Do not re-tighten the belt since there is a risk of exceeding the
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permitted working range in one of the directions. The belt tensioner
base setting only applies in the case of new timing belts. Re-
tightening of the belt can cause it to rip or flutter.
It is no longer possible to check the base setting once the adjustment tools and pin have been
removed (the spring forces of the valve train are exerted on the belt and change the position of the
belt tensioner).
Automatic Timing Belt Tensioner
Fig. 6: Identifying Automatic Timing Belt Tensioner

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Cylinder Head Attachments
Intake Manifold
The new Zetec-E engines are fitted with an intake manifold made of glass fibre reinforced plastic.
The ducts in the intake manifold are arranged to ensure that the intake distance is the same for
each cylinder.
Intake Manifold Attachments
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Fig. 7: Identifying Intake Manifold Attachments
Cylinder Block
Crankshaft
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The crankshaft is housed in five bearings and has a counterweight for each cylinder. The central
main bearing has two thrust half shells which axially guide the crankshaft and set the end float.
Crankshaft Bearings
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Fig. 8: Identifying Crankshaft Bearings
Connecting (ISC) rod bearings
The connecting rods are numbered one to four starting at the timing belt end. It is practically
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impossible to mix up the connecting rod bearing caps and connecting rods since the connecting
rod bearing caps are broken away from the connecting rod during production. The fracture
profile of a connecting rod bearing cap therefore only fits one of the connecting rods.
Crankcase Reinforcement
Lower crankcase
View of Crankcase Reinforcements
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Fig. 9: Identifying Crankcase Reinforcements

The crankcase reinforcements are designed to damp engine vibrations. This leads to a further
reduction in interior noise levels. The crankcase reinforcements are sealed against the cylinder
block by means of a flat carrier gasket.
Crankcase Reinforcement Spacers
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Fig. 10: Identifying Crankcase Reinforcement Spacers
The crankcase reinforcement spacers are needed to even out any excessive gap between the
transmission and the crankcase reinforcements.
Oil Pan
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Fig. 11: Identifying Oil Pan
The unit is closed off at the bottom by a drawn sheet metal oil pan which is directly fixed to the
crankcase reinforcements. A 3 mm wide bead of sealer ensures that the unit is leakproof.
Engine Control
Powertrain Control Module (PCM)
The PCM controls the Zetec-E engine. To enable it to do this, the PCM requires comprehensive
information regarding the current operating state of the engine. The PCM obtains this information
by means of numerous sensors.
The PCM controls:

the fully electronic (EI) ignition system
the sequential electronic fuel injection (SEFI)
the air-conditioning system in conjunction with the cooling system.
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DIAGNOSIS AND TESTING

ENGINE
REFER to ENGINE SYSTEM-GENERAL INFORMATION article .
GENERAL PROCEDURES
VALVE CLEARANCE
Material
MATERIAL SPECIFICATION
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Cable ties
Adjust
CAUTION: Exchange the tappets to correct the valve clearance.
CAUTION: Disconnect the battery ground cable.
NOTE: Do not remove the upper timing belt cover.
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Fig. 12: Removing Upper Timing Belt Cover
1. Undo the bolts in the upper timing belt cover.
CAUTION: Do not pull the spark plug connectors by the ignition

wires when removing them. If necessary pull off the
ignition wires from the ignition coils to prevent kinking
the ignition wires. Slightly twist the spark plug
connectors before removing them in order to loosen the
seals.
CAUTION: Pull off the spark plug connectors in line with the spark
plugs.
NOTE: Loosening sequence: from the outside to the inside, working

diagonally.
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2. Remove the cylinder head cover.

1. Pull off the spark plug connectors.
2. Detach the crankcase ventilation hose.
3. Unscrew the 10 bolts.
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Fig. 13: Pulling Off Spark Plug Connectors
CAUTION: Only rotate the engine on the crankshaft and in its

rotation direction.
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Fig. 14: Setting Engine To TDC On Cylinder Number 1
3. Set the engine to TDC on cylinder number 1.
NOTE: Note down each cylinder number and the valve clearances
measured.
4. Measure the valve clearance using feeler gauges.

Permitted valve clearance: inlet (0.11 - 0.18 mm)
Permitted valve clearance: exhaust (0.27 - 0.34 mm)
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Fig. 15: Measuring Valve Clearance Using Feeler Gauges
CAUTION: Only rotate the engine on the crankshaft.
5. Measure the valve clearance (continued).

Rotate the engine a further 180 degrees on the crankshaft in its rotation direction. In
this instance, the measuring sequence follows the firing order 1-3-4-2.
Repeat the previous steps for the other cylinders.
NOTE: Only carry out the following steps when the valve clearance
must be adjusted.
NOTE: Aim to set the valve clearances to the middle of the range (inlet
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0.15 mm; exhaust 0.30 mm)
6. Remove the camshafts. For additional information, refer to CAMSHAFT .
NOTE: The number on the tappet indicates the tappet thickness.
7. Determine the tappet thickness required.

Remove the adjusting tappet and read the thickness from the back side.
Determine the tappet thickness required and insert the correct tappet.
Inlet valves: tappet thickness required = thickness of currently installed tappet +

measured valve clearance - 0.15 mm.
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Exhaust valves: tappet thickness required = thickness of currently installed tappet +
measured valve clearance - 0.30 mm.
CAUTION: Set the piston on cylinder number 1 to approximately 25

mm before TDC.
8. Install the camshafts and camshaft timing belts. For additional information, refer to
CAMSHAFT .
NOTE: Turn the camshaft to measure the valve clearance.
NOTE: Do not attach the timing belt until the setting is in order.
9. Recheck the valve clearance after adjustment is complete.

10. Install the timing belt. For additional information, refer to TIMING BELT .
CAUTION: Use a blunt object (a plastic cable tie) to apply the

silicone grease, to avoid damaging the spark plug
connectors.
CAUTION: Push on the spark plug connectors, keeping them in line

with the spark plugs.
NOTE: Apply silicone grease to the inside of the spark plug

connectors to a depth of 5-10 mm.
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11. Install the cylinder head cover.

1. Insert the 10 bolts and tighten them in two stages.
Stage 1: 2 N.m.
Stage 2: 7 N.m.
4. Attach the crankcase ventilation hose.

5. Fit the spark plug connectors and make sure that they engage correctly.
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Fig. 16: Installing Spark Plug Connectors
NOTE: Check that the gasket on the upper timing belt cover is seated
correctly and adjust if necessary.
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Fig. 17: Installing Upper Timing Belt Cover
12. Install the upper timing belt cover.
NOTE: When the battery has been disconnected and reconnected,

some abnormal drive symptoms may occur while the vehicle
relearns its adaptive strategy. The vehicle may need to be
driven 16 km (10 miles) or more to relearn the strategy.
13. Connect the battery ground cable.

14. Check the fluid levels and adjust if necessary.
15. Check that the vacuum hoses and cables are routed correctly and fix in place using cable
ties.
IN-VEHICLE REPAIR
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INTAKE MANIFOLD
Removal
1. Release the fuel pressure. For additional information, refer to FUEL SYSTEM
PRESSURE RELEASE .
2. Unfasten the cable ties if necessary and install new ones when reinstalling.
3. Remove the generator. For additional information, refer to GENERATORS &
REGULATORS article .
4. Remove the air cleaner housing.
1. Pull off the mass air flow (MAF) sensor connector.
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2. Detach the crankcase ventilation hose.
3. Detach the intake hose.
Pull out the air cleaner housing from the rubber bushings.
Fig. 18: Pulling Off Mass Air Flow (MAF) Sensor Connector
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5. Detach the accelerator cable and the speed control cable (if equipped) from the throttle
body.
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Fig. 19: Detaching Accelerator Cable And Speed Control Cable
6. Remove the fuel pressure sensor. For additional information, refer to FUEL PRESSURE
SENSOR .
7. Detach the EGR valve and EGR pipe bracket.
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Fig. 20: Detaching EGR Valve And EGR Pipe Bracket
8. Pull off the vacuum hoses.
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Fig. 21: Removing Vacuum Hoses
9. Disconnect the fuel injector wiring.
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Fig. 22: Disconnecting Fuel Injector Wiring
10. Disconnect the camshaft position (CMP) sensor.
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Fig. 23: Disconnecting Camshaft Position (CMP) Sensor
11. Detach the fuel line.
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Fig. 24: Detaching Fuel Line
12. Remove the engine lifting eye.
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Fig. 25: Removing Engine Lifting Eye
13. Detach the intake manifold (graphic shows engine removed).

1. Remove the intake manifold studs on the front end of the engine.
2. Remove the five bolts and two nuts.
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Fig. 26: Removing Intake Manifold
Installation
1. Install the intake manifold (graphic shows engine removed).
NOTE: Stud tightening torque = 10 N.m.
1. Screw in the intake manifold studs.

2. Tighten the five bolts and two nuts.
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Fig. 27: Installing Intake Manifold
2. Install the engine lifting eye.
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Fig. 28: Installing Engine Lifting Eye
3. Install the generator. For additional information, refer to GENERATORS &

REGULATORS article .
4. Install the fuel pressure sensor. For additional information, refer to FUEL PRESSURE
SENSOR .
5. Install the fuel line.
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Fig. 29: Installing Fuel Line
6. Connect the camshaft position (CMP) sensor.
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Fig. 30: Connecting Camshaft Position (CMP) Sensor
7. Connect the fuel injector wiring.
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Fig. 31: Connecting Fuel Injector Wiring
8. Install the vacuum hoses.
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Fig. 32: Installing Vacuum Hoses
9. Install the EGR valve with a new gasket and EGR pipe bracket.
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Fig. 33: Installing EGR Valve With New Gasket And EGR Pipe Bracket
10. Install the accelerator cable and the speed control cable (if equipped) to the throttle body.
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Fig. 34: Installing Accelerator Cable And Speed Control Cable
11. Install the air cleaner housing.

Insert the air filter housing into the rubber bushings.
2. Attach the mass air flow (MAF) sensor connector.

3. Attach the crankcase ventilation hose.
4. Attach the intake hose.
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Fig. 35: Installing Mass Air Flow (MAF) Sensor Connector
12. If necessary, install new cable ties when reinstalling.

13. Connect the battery ground cable.
CRANKSHAFT FRONT SEAL
Special Tool(s)
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Fig. 36: Identifying Special Tools
Material
Engine oil WSS-M2C153-H
Removal
1. Remove the timing belt. For additional information, refer to TIMING BELT .
NOTE: FRONT marking and thrust washer installation position.
2. Detach the crankshaft timing belt.

1. Remove the crankshaft pulley hub.
2. Remove the timing belt thrust washer.
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Fig. 37: Removing Crankshaft Pulley Hub
3. Using the special tool remove the crankshaft front oil seal.
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Fig. 38: Removing Crankshaft Front Oil Seal
Installation
NOTE: Use the crankshaft pulley hub bolt and washer.
1. Using the special tool install the crankshaft front oil seal.
Coat the oil seal lip and crankshaft running surface with engine oil.
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Fig. 39: Installing Crankshaft Front Oil Seal
NOTE: FRONT marking and thrust washer installation position.
2. Install the crankshaft pulley hub.

1. Install the timing belt thrust washer.
2. Install the crankshaft pulley hub.
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Fig. 40: Installing Crankshaft Pulley Hub
VALVE SPRINGS
Special Tool(s)
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Removal
1. Remove the valve tappets.
WARNING: Always wear protective goggles when working with

compressed air. This can prevent injury. Failure to
follow these instructions may result in personal injury.
2. Using special tools, remove the valve springs.

Apply compressed air to the cylinders.
Compress the valve springs and remove the valve collets.
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Remove the valve spring retainers and the valve springs and place them in order to one
side. To remove the collets use some grease and a small screw driver.
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Fig. 42: Removing Valve Springs
Installation
NOTE: Check that there is no dirt or particles within the valve stem
grooves. Check the seating of the valve collets.
1. Using special tools install the valve springs.

Insert the valve springs and the valve spring retainers.
Compress the valve springs and install the valve collets.
Disconnect and remove the air supply.
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Fig. 43: Installing Valve Springs
2. Install the valve tappets.
VALVE SEALS
Special Tool(s)
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Material
Removal
1. Remove the camshafts. For additional information, refer to CAMSHAFTS .

Remove the valve tappets and place them in order to one side.
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WARNING: Always wear protective goggles when working with
compressed air. This can prevent injury. Failure to
follow these instructions may result in personal injury.
2. Unscrew the spark plug on cylinder No. 1 and connect the compressed air supply.
CAUTION: Use compressed air at 7 to 10 bars.
3. Using the special tools and apply compressed air to the cylinder.
Using the special tools, compress the valve springs and remove the valve collets using
some grease and a small screwdriver.
Remove the valve spring retainers and the valve springs.
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Fig. 45: Removing Valve Spring Retainers And Valve Springs
NOTE: Place all parts in order to one side.
4. Remove the valve springs.

5. Using special tools, remove the valve stem seals.
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Fig. 46: Removing Valve Stem Seals
Installation
1. Valve stem seal installation sleeve.
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Fig. 47: Identifying Valve Stem Seal Installation Sleeve

2. Using the special tool, install the valve stem oil seals.
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Fig. 48: Installing Valve Stem Oil Seals
NOTE: Check the seating of the valve collets.
3. Using the special tools, install the valve springs.

Compress the valve springs and install the valve collets using some grease and a small
screwdriver.
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NOTE: Do not tighten the spark plug at this stage.
4. Disconnect the compressed air supply and screw in the spark plug.
5. Repeat appropriate steps for all the other cylinders.
6. Coat the valve tappets with engine oil and insert them.
7. Install the camshafts. For additional information, refer to CAMSHAFT .
VALVES
Special Tool(s)
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2002 Ford Focus LX
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MY
2002 Ford Focus LX

Material
Removal
NOTE: Place the cylinder head onto a clean support on the workbench.
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NOTE: Place wooden wedges in the combustion chamber recesses in
the cylinder head to stop the valves from opening during
removal.
1. Using the special tools, compress the valve springs.

Compress the valve springs and remove the valve collets using some grease and a small
screwdriver.
Remove the valve spring retainers and the valve springs.
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2002 Ford Focus LX
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Fig. 51: Removing Valve Spring Retainers And Valve Springs
NOTE: Place all parts in order to one side.
2. Remove the valve springs.

3. Using the special tools, remove the valve stem seals.
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2002 Ford Focus LX
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4. Remove the valves and place them in order to one side.

Installation
NOTE: Follow the procedure recommended by the grinding paste

manufacturer.
NOTE: Install each valve in the same position from which it was
removed.
1. Regrind the valves.

2. Thoroughly clean off any traces of sealer and grinding paste from all components.
3. Coat the valve stems with engine oil and insert them in the valve guides.
4. Valve stem seal installation sleeve.
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2002 Ford Focus LX
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Fig. 53: Identifying Valve Stem Seal Installation Sleeve

5. Using the special tool, install new valve stem oil seals.
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2002 Ford Focus LX
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Fig. 54: Installing New Valve Stem Oil Seals
NOTE: Check the seating of the valve collets.
6. Using the special tools, install the valve springs.

Compress the valve springs and install the valve collets using some grease and a small
screwdriver.
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2002 Ford Focus LX
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CAMSHAFTS
Special Tool(s)
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2002 Ford Focus LX
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Material
Cable ties
Removal
1. Remove the intake pipe.
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2002 Ford Focus LX
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Fig. 57: Removing Intake Pipe
2. Detach the accelerator cable and the speed control cable (if equipped).
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2002 Ford Focus LX
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Fig. 58: Removing Accelerator Cable And Speed Control Cable
4. Remove the camshaft timing pulleys.
Prevent turning using the special tool.
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2002 Ford Focus LX
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Fig. 59: Removing Camshaft Timing Pulleys
NOTE: Loosening sequence.
5. Unscrew the bolts of the camshaft bearing caps evenly in several stages two turns at a time.
Remove the oil seals.
Remove the camshafts.
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2002 Ford Focus LX
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Fig. 60: Identifying Loosening Sequence Of Camshaft Bearing Caps Bolts
Installation
NOTE: Identification numbers are provided on the outer face of the

camshaft bearing caps.
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2002 Ford Focus LX
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Fig. 61: Applying Sealant To Camshaft Bearing Cap
1. Apply sealant to camshaft bearing cap numbers 0 and 5 in the areas shown.
2. Turn the crankshaft to approximately 60 degrees before TDC on cylinder number 1.
NOTE: Lay the camshaft in place so that none of the cams is at full lift.
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2002 Ford Focus LX
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Fig. 62: Lubricating Camshaft And Camshaft Bearing Caps With Engine Oil
3. Lubricate the camshaft and camshaft bearing caps with engine oil.
NOTE: Screw in the camshaft bearing cap bolts evenly, in the

sequence shown, a half turn at a time and tighten them in two
stages.
4. Tighten the bolts of the camshaft bearing caps.

Stage 1: 10 N.m.
Stage 2: 19 N.m.
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2002 Ford Focus LX
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Fig. 63: Identifying Tightening Sequence Of Camshaft Bearing Caps Bolts
5. Check the valve clearance and if necessary adjust. For additional information, refer to
Valve Clearance .
6. Install the camshaft oil seals.
Lubricate the camshaft and oil seal lip with engine oil.
Using the special tool install a new oil seal.
NOTE: Do not tighten the bolts. The camshaft timing pulleys must
be able to turn freely on the camshafts.
Install the camshaft timing pulleys.
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2002 Ford Focus LX
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Fig. 64: Installing Camshaft Oil Seals
8. Lower the vehicle.
9. Attach the accelerator cable and the speed control cable (if equipped).
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2002 Ford Focus LX
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10. Install the intake pipe.
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2002 Ford Focus LX
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Fig. 66: Installing Intake Pipe

11. Standard finishing operations

Connect the battery ground cable.
Check fluid levels and correct if necessary.
Check the routing of vacuum hoses and cables and secure them with cable ties.
Check fluid levels again and correct if necessary.
CAMSHAFT SEAL
Special Tool(s)
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2002 Ford Focus LX
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Material
Gasket maker WSK-M2G348-A5
Removal
2. Remove the camshaft pulleys.
Remove the bolts.
3. Remove camshaft bearing caps numbers 0 and 5.

Remove the camshaft oil seals.
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2002 Ford Focus LX
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Fig. 68: Removing Camshaft Bearing Caps
Installation
1. Thinly coat camshaft bearing caps numbers 0 and 5 with gasket maker.
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2002 Ford Focus LX
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Fig. 69: Applying Sealant To Camshaft Bearing Caps
2. Install a new exhaust camshaft oil seal.

3. Install camshaft bearing caps numbers 0 and 5.
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2002 Ford Focus LX
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Fig. 70: Installing Camshaft Bearing Caps
4. Using the special tool, press in the intake and exhaust camshaft oil seals.
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2002 Ford Focus LX
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Fig. 71: Installing Intake And Exhaust Camshaft Oil Seals
NOTE: Do not tighten the bolts yet.
5. Slide the timing belt pulleys onto the camshafts and screw in the timing belt pulley bolts.
6. Install a new timing belt. For additional information, refer to TIMING BELT .
TIMING BELT
Special Tool(s)
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2002 Ford Focus LX
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Material
Never Seeze WSD-M13P8-A1
Cable ties
Removal
1. General Instructions.
The positions of the engine mounting and the engine roll restrictor are described
looking from the transmission towards the engine.
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2002 Ford Focus LX
If necessary, use Special Tool 412-108 to remove coolant and ventilation hoses.
Owing to special model variants, some steps do not apply to all vehicles. These are
clearly marked in the text.
If necessary, cut the cable tie and install new on installation.
CAUTION: Disconnect the battery negative cable.
2. Raise and support the vehicle.

3. Detach the drive belt cover.
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Fig. 73: Detaching Drive Belt Cover
NOTE: Mark the drive belt running direction.
4. Remove the drive belt.

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2002 Ford Focus LX
1. Loosen the bolts on the coolant pump pulley.

2. Slacken the drive belt by turning clockwise and remove it.
Detach the coolant pump belt pulley.
4. Detach the multi-groove belt idler pulley.
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Fig. 74: Removing Drive Belt
5. Detach the crankshaft pulley/vibration damper.
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2002 Ford Focus LX
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Fig. 75: Detaching Crankshaft Pulley/Vibration Damper
CAUTION: The removal of the lower part of the engine front cover is
necessary to avoid damage to the timing belt.
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2002 Ford Focus LX
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Fig. 76: Detaching Lower Timing Belt Cover
6. Detach the lower timing belt cover.

8. Detach the coolant expansion tank and lay it to one side.
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2002 Ford Focus LX
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Fig. 77: Removing Coolant Expansion Tank
9. Remove the PAS reservoir and lay it to one side.
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2002 Ford Focus LX
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Fig. 78: Removing PAS Reservoir
CAUTION: Insert the wooden block between the oil pan and the jack.
10. Position the jack with the wooden block under the oil pan and raise so that the front engine
mounting is free from load.
NOTE: Mark the position of the engine mounting.
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2002 Ford Focus LX
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Fig. 79: Removing Front Engine Mounting
11. Remove the front engine mounting.

12. Detach the timing belt upper cover.
Leave the timing belt cover in its installed position.
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2002 Ford Focus LX
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Fig. 80: Removing Timing Belt Upper Cover
13. Detach the timing belt center cover/front engine mounting bracket.
Remove the timing belt upper cover.
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2002 Ford Focus LX
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Fig. 81: Removing Timing Belt Center Cover/Front Engine Mounting Bracket
CAUTION: Do not pull the cable when removing the spark plug
connectors. If necessary, remove the ignition cables from
the ignition coil to avoid kinking the cables. Turn the
spark plug connectors slightly before removing to loosen
the seal.
plugs.
NOTE: Loosening sequence: from the outside to the inside, working

diagonally.
14. Remove the cylinder head cover.

1. Pull off the spark plug connectors.
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2002 Ford Focus LX
2. Detach the PCV hose.

3. Remove ten bolts.
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Fig. 82: Pulling Off Spark Plug Connectors
15. Remove the spark plugs.

16. Turn the engine to TDC on cylinder number 1.
17. Detension the timing belt.
1. Unscrew the bolt four turns.
2. Position the tensioner so the locating tab is at approximately the 4 o'clock position.
3. Line up the hex key slot in the tensioner adjusting washer with the pointer that is
located behind the pulley.
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2002 Ford Focus LX
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Fig. 83: Detensioning Timing Belt
18. Remove the timing belt.

19. Slacken the camshaft timing pulleys.
Prevent from turning using the special tool.
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2002 Ford Focus LX
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Fig. 84: Slackening Camshaft Timing Pulleys
Installation
NOTE: Do not tighten the bolts. The camshaft timing pulleys must be
able to turn freely on the camshafts.
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2002 Ford Focus LX
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Fig. 85: Inserting Special Tool Into Camshafts
1. Turn the camshafts to ignition position on cylinder number 1 and insert the special tool into
the camshafts.
NOTE: Rotate the crankshaft clockwise.
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2002 Ford Focus LX
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Fig. 86: Rotating Crankshaft For Positioning Cylinder Number 1 To TDC Position
2. Rotate the crankshaft to TDC on cylinder number 1.
NOTE: Cylinders No. 1 and No. 4 are at TDC when the Woodruff key
points straight up.
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2002 Ford Focus LX
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Fig. 87: Removing Blanking Plug
3. Remove the blanking plug, completely screw in the special tool and auto-align the
crankshaft to TDC.
CAUTION: Do not kink the timing belt (do not bend the timing belt
less than a diameter of 35 mm).
CAUTION: Do not rotate the crankshaft, check that it is still resting

against the timing pin.
NOTE: The lug of the belt tensioner must not be hooked into the sheet
metal cover during timing belt installation.
4. Position a new timing belt in place.

Starting from the crankshaft timing belt pulley and working counterclockwise, position
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2002 Ford Focus LX
the timing belt in place while keeping it under tension.
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Fig. 88: Installing Timing Belt

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2002 Ford Focus LX
CAUTION: Incorrect timing belt tension will cause incorrect valve

timing.
5. Pre tension the timing belt.

1. Rotate the tensioner locating tab counterclockwise and insert the locating tab into the
slot in the rear timing cover.
2. Position the hex key slot in the tensioner adjusting washer to the 4 o'clock position.
3. Tighten the attaching bolt enough to seat the tensioner firmly against the rear timing
cover, but still allow the tensioner adjusting washer to be rotated using a 6mm hex key.
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Fig. 89: Tightening Attaching Bolt For Seating Tensioner Against Rear Timing
Cover
CAUTION: Tension the timing belt, working counterclockwise.

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2002 Ford Focus LX
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Fig. 90: Rotating Adjusting Washer Counterclockwise Until Notch In Pointer
Centered Over Index Line On Locating Tab
6. Using the hex key, rotate the adjusting washer counterclockwise until the notch in the
pointer is centered over the index line on the locating tab (the pointer will move clockwise
during adjustment).
7. While holding the adjusting washer in position, tighten the bolt.
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2002 Ford Focus LX
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Fig. 91: Tightening Bolt
CAUTION: Do not tighten the camshaft timing pulley bolts against

Special Tool 303-465; use Special Tool 303-098 to prevent
movement.
NOTE: The crankshaft must remain at TDC on cylinder number 1.
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2002 Ford Focus LX
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Fig. 92: Tightening Camshaft Timing Pulleys Bolts
8. Tighten the bolts of the camshaft timing pulleys.

9. Unscrew and remove Special Tool 303-574.
10. Remove Special Tool 303-465 from the camshafts.
NOTE: Turn the crankshaft two revolutions in the normal direction of

rotation.
11. Check the valve timing by inserting the special tool. Correct it if necessary.
Screw in Special Tool 303-574 and make sure that the crankshaft is touching it.
Insert Special Tool 303-465 into the camshafts; if necessary loosen the timing pulleys
and correct the camshaft alignment.
Detach the special tools.
12. Screw in and tighten the blanking plug.
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2002 Ford Focus LX
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Fig. 93: Tightening Blanking Plug

silicone grease, to avoid damaging the spark plug
connectors.

NOTE: Coat the inside of the spark plug connectors with silicone
grease to a depth of 5-10 mm.
13. Install the cylinder head cover and spark plugs.

1. Tighten the bolts in two stages.
Stage 1: 2 N.m
Stage 2: 7 N.m
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2002 Ford Focus LX
4. Attach the PCV hose.

5. Coat the spark plug thread with Never Seeze, screw in the spark plugs and push in
the spark plug connector until it engages.
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Fig. 94: Installing Spark Plug And Spark Plug Connector
NOTE: Put the upper timing belt cover together with the center timing
belt cover in place.
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2002 Ford Focus LX
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Fig. 95: Installing Timing Belt Center Cover/Front Engine Mounting Bracket
14. Attach the timing belt center cover/front engine mounting bracket.
NOTE: Check the seating of the timing belt upper cover gasket and
correct it if necessary.
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2002 Ford Focus LX
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Fig. 96: Installing Timing Belt Upper Cover
15. Attach the timing belt upper cover.

16. Install the front engine mounting.
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2002 Ford Focus LX
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Fig. 97: Installing Front Engine Mounting
17. Connect the PAS reservoir.
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2002 Ford Focus LX
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Fig. 98: Connecting PAS Reservoir
18. Install the coolant expansion tank.
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2002 Ford Focus LX
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Fig. 99: Installing Coolant Expansion Tank
19. Pull the jack out towards the front of the vehicle.
21. Attach the lower timing belt cover.
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2002 Ford Focus LX
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Fig. 100: Installing Lower Timing Belt Cover
22. Attach the crankshaft pulley/vibration damper.
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2002 Ford Focus LX
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Fig. 101: Installing Crankshaft Pulley/Vibration Damper
NOTE: Direction of travel on a used drive belt.
23. Install the drive belt.

1. Attach the multi-groove belt idler pulley.
NOTE: Screw in the bolts only until it starts to take up, do not
tighten them.
Attach the coolant pump pulley.

3. Install the drive belt by turning clockwise and tension it.
4. Tighten the bolts on the coolant pump pulley.
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2002 Ford Focus LX
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Fig. 102: Installing Drive Belt
24. Attach the drive belt cover.
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2002 Ford Focus LX
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Fig. 103: Installing Drive Belt Cover

26. Standard finishing operations:

Connect the battery negative cable.
EXHAUST MANIFOLD
Removal
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2002 Ford Focus LX

2. Detach the catalyst bracket and disconnect the plugs for the heated oxygen sensor (H02S).
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Fig. 104: Removing Catalyst Bracket And Disconnecting Plugs For Heated Oxygen
Sensor (HO2S)

4. Detach the heat shield.
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2002 Ford Focus LX
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Fig. 105: Removing Heat Shield

1. Pull out the plug of the mass air flow (MAF) sensor.
2. Detach the positive crankcase ventilation (PCV) hose.
Remove the air cleaner housing from the rubber bushings.
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2002 Ford Focus LX
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Fig. 106: Pulling Out Plug Of Mass Air Flow (MAF) Sensor
6. Remove and discard the exhaust gas recirculation (EGR) tube.

7. Detach the exhaust manifold from the catalyst.
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2002 Ford Focus LX
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Fig. 107: Removing Exhaust Manifold From Catalyst
8. Detach the exhaust manifold from the cylinder head.
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2002 Ford Focus LX
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Fig. 108: Removing Exhaust Manifold From Cylinder Head
Installation
1. Attach the exhaust manifold to the cylinder head using the alignment spacers with the two
outside bolts and a new manifold gasket.
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2002 Ford Focus LX
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Fig. 109: Installing Exhaust Manifold To Cylinder Head
CAUTION: Always follow the correct installation sequence for the

catalytic converter in order to prevent damage.
CAUTION: Do not allow debris to fall into the exhaust manifold.
NOTE: Examine the threads in the exhaust catalyst cone and EGR.
Clean as required.
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2002 Ford Focus LX
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Fig. 110: Loosening Bracket Of Catalytic Converter
2. Loosen the bracket for the catalytic converter so that it can move freely.
NOTE: Use a new gasket.
NOTE: Do not fully tighten the nuts/bolts at this stage.
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2002 Ford Focus LX
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Fig. 111: Installing Catalytic Converter On The Exhaust Manifold
3. Position the catalytic converter on the exhaust manifold using new hardware.
5. Using a nut and bolt, temporarily secure the catalytic converter to the bracket at the rear.
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2002 Ford Focus LX
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Fig. 112: Securing Catalytic Converter To Bracket At Rear
6. Tighten the catalytic converter to the exhaust manifold.
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2002 Ford Focus LX
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Fig. 113: Tightening Catalytic Converter To Exhaust Manifold
NOTE: Always use a new catalyst to EGR valve pipe assembly.
NOTE: Loosely assemble the pipe to both the EGR valve and the
exhaust catalyst before tightening the unions.
7. Attach the catalytic converter.

1. Tighten the bolts on the catalytic converter bracket.
2. Install a new EGR-pipe.
3. Attach the heat shield.
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2002 Ford Focus LX
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Fig. 114: Installing Heat Shield
8. Attach the bracket for the catalytic converter.

Tighten the bolts.
Remove the temporary bolt from the rear catalytic converter bracket.
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2002 Ford Focus LX
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Fig. 115: Installing Bracket Of Catalytic Converter

10. Attach the air filter housing.
Press the air filter housing into the rubber bushings.
2. Push on the mass air flow (MAF) sensor multiplug.

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2002 Ford Focus LX
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Fig. 116: Connecting Mass Air Flow (MAF) Sensor
CYLINDER HEAD
Special Tool(s)
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2002 Ford Focus LX
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Material
Cable ties
Coolant ESD-M97B49-A
Sealant WS-M4G348-A5
Sealant remover WSK-M2G348-A4
Removal
1. General remarks.
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2002 Ford Focus LX
PRESSURE RELEASE .
CAUTION: Disconnect the battery negative cable.
3. If necessary, separate cable ties and install on installation.
WARNING: To prevent the risk of scalding, place a thick cloth over

the filler cap before opening the cooling circuit. Failure
to do so may result in personal injury.
4. Open the coolant reservoir.
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WARNING: Danger of scalding if the engine is warm.
6. Drain the coolant from the radiator.

Install the radiator drain plug after draining the coolant.
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2002 Ford Focus LX
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Fig. 118: Installing Radiator Drain Plug
7. Detach the brake booster pipe from the intake manifold.

Release the quick release coupling and pull out the brake booster pipe.
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2002 Ford Focus LX
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Fig. 119: Removing Brake Booster Pipe From Intake Manifold
8. Disconnect the oil pressure switch connector.
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2002 Ford Focus LX
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Fig. 120: Disconnecting Oil Pressure Switch Connector

1. Pull out the plug of the mass air flow (MAF) sensor.
Remove the air cleaner housing from the rubber bushings.
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2002 Ford Focus LX
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Fig. 121: Pulling Out Plug Of Mass Air Flow (MAF) Sensor
1. Unhook the cable.
2. Pull off the plastic clip and lay the accelerator cable to one side.
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2002 Ford Focus LX
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12. Detach the EGR valve and EGR pipe bracket.
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2002 Ford Focus LX
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Fig. 123: Removing EGR Valve And EGR Pipe Bracket
13. Pull off the vacuum hoses.
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2002 Ford Focus LX
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Fig. 124: Pulling Off Vacuum Hoses
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2002 Ford Focus LX
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15. Disconnect the camshaft position (CMP) sensor.
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2002 Ford Focus LX
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Fig. 126: Disconnecting Camshaft Position (CMP) Sensor
WARNING: Escaping fuel. Observe the safety regulations for

working with fuel.
16. Detach the fuel lines.

Detach the ground cable.
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2002 Ford Focus LX
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Fig. 127: Detaching Ground Cable
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2002 Ford Focus LX
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Fig. 128: Removing Heat Shield
18. Detach the thermostat housing.
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2002 Ford Focus LX
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Fig. 129: Removing Thermostat Housing
19. Detach the catalytic converter from the exhaust manifold.
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2002 Ford Focus LX
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Fig. 130: Removing Catalytic Converter From Exhaust Manifold
20. Detach the power steering pipe bracket and the oil level indicator tube.
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2002 Ford Focus LX
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Fig. 131: Removing Power Steering Pipe Bracket And Oil Level Indicator Tube
21. Detach the bracket from the power steering pump.

1. Remove the lower studs.
2. Remove the upper bolts.
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2002 Ford Focus LX
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Fig. 132: Detaching Bracket From Power Steering Pump
22. Detach the generator.

1. Loosen the bolt.
2. Remove the bolt.
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2002 Ford Focus LX
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Fig. 133: Removing Generator
23. Unscrew the upper bolt from the generator bracket.
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2002 Ford Focus LX
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Fig. 134: Removing Upper Bolt From Generator Bracket
25. Unscrew the bolts of the camshaft bearing caps evenly in several stages two turns at a time.
Remove the camshafts.
Remove the tappets and keep them in order.
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2002 Ford Focus LX
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CAUTION: Mark the bolts to be reused with one or two punch marks.
Bolts can be reused twice. Discard bolts as necessary.
CAUTION: The cylinder head must be cooled to ambient

temperature.
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2002 Ford Focus LX
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Fig. 136: Identifying Loosening Sequence Of Cylinder Head Bolts
26. Remove the cylinder head bolts.

27. Remove the cylinder head.
Installation
1. General remarks.
If necessary, use Special Tool 412-108 to install coolant and ventilation hoses.
2. Preparatory operations
CAUTION: Do not damage the cylinder liner surfaces. Remove

carbon deposits from the top edge of the cylinder.
Remove gasket residue with seal remover and a spatula.

Thoroughly clean the threaded holes of the cylinder head bolts.
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2002 Ford Focus LX
3. Check the cylinder head deformation. For additional information, refer to ENGINE
SYSTEM-GENERAL INFORMATION .
4. Make up two locating studs as shown.
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Fig. 137: Identifying Stud
5. Install a new cylinder head cover gasket on the cylinder block.

1. Position a new cylinder head gasket.
2. Insert the fabricated locating studs.
3. Check that the locating studs are seated correctly.
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2002 Ford Focus LX
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Fig. 138: Installing New Cylinder Head Cover Gasket On Cylinder Block
6. Install the cylinder head.

Position the cylinder head on the cylinder block.
CAUTION: Do not retighten the cylinder head bolts.
7. Tighten the cylinder head bolts in three stages in the sequence indicated.
Stage 1: 20 N.m
Stage 2: 40 N.m
Stage 3: 90 degrees.
Apply engine oil to the tappets and insert them.
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2002 Ford Focus LX
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Fig. 139: Identifying Tightening Sequence Of Cylinder Head Bolts
8. Apply sealant to camshaft bearing cap numbers 0 and 5 in the areas shown.
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2002 Ford Focus LX
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Fig. 140: Applying Sealant To Camshaft Bearing Cap
9. Turn the crankshaft to approximately 60 degrees before TDC on cylinder number 1.
NOTE: Identification numbers are provided on the outer face of the

10. Lay the camshaft in place so that none of the cams is at full lift.
Lubricate the camshaft and camshaft bearing caps with engine oil.
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2002 Ford Focus LX
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Fig. 141: Identifying Marking On Outer Face Of Camshaft Bearing Caps
NOTE: Screw in the camshaft bearing cap bolts evenly in several

stages, in the sequence shown, a half turn at a time and tighten
them in two stages.
11. Tighten the bolts of the camshaft bearing caps.

Stage 1: 10 N.m
Stage 2: 19 N.m
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2002 Ford Focus LX
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Fig. 142: Identifying Tightening Sequence Of Camshaft Bearing Cap Bolts
Valve Clearance .
Lubricate the camshaft and oil seal lip with engine oil.
Using the special tool install a new oil seal.
NOTE: Do not tighten the bolts. The camshaft timing pulleys must
be able to turn freely on the camshafts.
Attach the timing belt pulleys.
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2002 Ford Focus LX
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16. Attach the power steering pump bracket.
1. Screw in the upper bolts.
2. Insert the lower studs.
Tighten the bolts and nuts.
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2002 Ford Focus LX
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Fig. 144: Installing Power Steering Pump Bracket
17. Install the upper bolt to the generator bracket.
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2002 Ford Focus LX
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Fig. 145: Installing Upper Bolt Of Generator Bracket
18. Attach the generator.
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2002 Ford Focus LX
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Fig. 146: Installing Generator
19. Attach the oil level indicator tube and the power steering pipe bracket.
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2002 Ford Focus LX
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Fig. 147: Installing Oil Level Indicator Tube And Power Steering Pipe Bracket
20. Attach the catalytic converter to the exhaust manifold.
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2002 Ford Focus LX
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Fig. 148: Installing Catalytic Converter To Exhaust Manifold
21. Attach the thermostat housing with new gasket.
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2002 Ford Focus LX
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Fig. 149: Installing Thermostat Housing With New Gasket
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2002 Ford Focus LX
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Fig. 150: Installing Heat Shield
23. Attach the fuel lines.
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2002 Ford Focus LX
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Fig. 151: Installing Fuel Lines
24. Connect the camshaft position (CMP) sensor.
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2002 Ford Focus LX
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Fig. 152: Connecting Camshaft Position (CMP) Sensor
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2002 Ford Focus LX
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26. Attach the EGR valve with a new gasket and EGR pipe bracket.
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2002 Ford Focus LX
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Fig. 154: Installing EGR Valve With New Gasket And EGR Pipe Bracket
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2002 Ford Focus LX
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28. Push on the vacuum hoses.
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2002 Ford Focus LX
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Fig. 156: Connecting Vacuum Hoses
29. Attach the air filter housing.


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2002 Ford Focus LX
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Fig. 157: Connecting Mass Air Flow (MAF) Sensor Multiplug

31. Push on the oil pressure switch electrical connector.
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2002 Ford Focus LX
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Fig. 158: Connecting Oil Pressure Switch Electrical Connector
32. Attach the brake booster pipe and the PCV hose to the intake manifold.
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2002 Ford Focus LX
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Fig. 159: Installing Brake Booster Pipe And PCV Hose To Intake Manifold

33. Standard finishing operations

Connect the battery negative cable.
Top up the coolant. For additional information, refer to ENGINE COOLING .
Close the coolant expansion tank.
Check fluid levels again and correct if necessary.
MY
2002 Ford Focus LX
NOTE: The engine oil temperature must be at least 80°C.
Change the engine oil and the oil filter. For additional information, refer to
GENERAL SPECIFICATIONS .
OIL PAN
Material
Sealant, oil sump WSE-M4G323-A6
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Studs M6 x 20
Removal
1. Remove the catalytic converter.

2. Drain the engine oil at the drain plug and remove the oil pan bolts (shown with engine
removed).
MY
2002 Ford Focus LX
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Fig. 160: Removing Oil Pan Bolts
CAUTION: Do not damage the mating faces.
3. Remove the oil pan (shown with engine removed).

Separate the oil pan from the lower crankcase using a sharp spatula. Release the oil
pan from the lower crankcase by tapping slightly against the tightened drain plug with
a rubber hammer.
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2002 Ford Focus LX
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Fig. 161: Separating Oil Pan From Lower Crankcase
Installation
NOTE: Do not damage the mating faces.
Clean the mating faces.
NOTE: Mating faces must be free from oil and sealant residue.
Clean all traces of oil residue and oil sludge from the oil pan.
CAUTION: Use studs. Sealer in the dead end bores can cause
damage to the ladder frame.
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2002 Ford Focus LX
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Fig. 162: Installing Studs On Dead End Bores
2. Install 10 studs, M6 x 20, in the shown dead end bores.
NOTE: Attach the oil pan within 10 minutes of applying sealant.
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2002 Ford Focus LX
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Fig. 163: Applying Bead Of Sealant To Oil Pan Mating Face
3. Apply a 3 mm bead of sealant to the oil pan mating face.
NOTE: Do not remove the oil pan, after the first contact with the ladder
frame.
NOTE: Tightening sequence.
4. Attach the oil pan and tighten the bolts in two stages. Fit the drain plug (shown with engine
removed).
Stage 1: 6 N.m
Stage 2: 10 N.m
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2002 Ford Focus LX
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Fig. 164: Identifying Tightening Sequence Of Oil Pan Bolts
5. Install the catalytic converter.

6. Fill with engine oil.
Fill capacity and engine oil according to specifications.
CRANKSHAFT REAR SEAL
Special Tool(s)
MY
2002 Ford Focus LX
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Material
High temperature grease ESD-M1C220-A
Removal
Vehicles with manual transaxle
1. Remove the clutch. For additional information, refer to CLUTCHES article .
Vehicles with automatic transaxle
2. Remove the automatic transaxle. For additional information, refer to AUTOMATIC

TRANSAXLE/TRANSMISSION .
MY
2002 Ford Focus LX
All vehicles
3. Using the special tool, remove the flywheel/drive plate.
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Fig. 166: Removing Flywheel/Drive Plate
4. Using the special tool, remove the oil seal.
MY
2002 Ford Focus LX
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Fig. 167: Removing Oil Seal
Installation
All vehicles
1. Using the special tool, install the oil seal.

Install three flywheel bolts.
MY
2002 Ford Focus LX
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Fig. 168: Installing Oil Seal
NOTE: Remove any traces of thread-locking compound from the

threaded bores on the crankshaft.
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2002 Ford Focus LX
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Fig. 169: Installing Flywheel/Drive Plate
2. Using the special tool, install the flywheel/drive plate.
Vehicles with manual transaxle
3. Install the clutch. For additional information, refer to CLUTCHES article .
Vehicles with automatic transaxle
4. Install the automatic transaxle. For additional information, refer to AUTOMATIC

REMOVAL
ENGINE - VEHICLES WITH: MTX-75/MANUAL TRANSAXLE
MY
2002 Ford Focus LX
Special Tool(s)
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Material
MY
2002 Ford Focus LX
Cable ties
Removal
All Vehicles
1. General remarks.
Owing to special model variants, some job steps do not apply to all vehicles. These are
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If necessary, separate the cable ties and renew on installation.
PRESSURE RELEASE .

to do so can result in injury.
3. Open the coolant expansion tank.
CAUTION: Disconnect the battery positive and negative cables.

Remove the battery.
4. Remove the battery tray and detach the ground cable.

1. Unclip and separate the connector.
2. Unclip the wiring harness.
3. Unscrew the bolts.
4. Detach the positive and negative cables.
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2002 Ford Focus LX
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Fig. 171: Removing Battery Tray And Ground Cable

1. Pull off the plug of the mass air flow (MAF) sensor.
Remove the air cleaner housing from the rubber bushing.
MY
2002 Ford Focus LX
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Fig. 172: Pulling Off Plug Of Mass Air Flow (MAF) Sensor
6. Detach the ground cable.
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2002 Ford Focus LX
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Fig. 173: Removing Ground Cable
NOTE: The resonator is a push fit in the bracket.
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2002 Ford Focus LX
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Fig. 174: Removing Air Cleaner Intake With Resonator
7. Remove the air cleaner intake with resonator.

9. Drain the coolant (shown from below).

Install the drain plug after draining.
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2002 Ford Focus LX
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Fig. 175: Installing Drain Plug
10. Drain the engine oil.

Install the drain plug after draining.
11. Partially lower the vehicle.
NOTE: Stop from turning using an Allen key.
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2002 Ford Focus LX
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Fig. 176: Slackening Suspension Strut Nuts
12. Slacken the suspension strut nuts by five turns on both sides.
13. Remove both front wheels and tires. .
14. Lock the driver's gear shift lever using the special tool.
Move the shift lever to neutral.
Detach the shift lever cover and insert the special tool.
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2002 Ford Focus LX
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Fig. 177: Detaching Shift Lever Cover And Inserting Special Tool
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2002 Ford Focus LX
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16. Pull off the connectors of the EI coil and the radio interference filter.
MY
2002 Ford Focus LX
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Fig. 179: Removing Connectors Of EI Coil And Radio Interference Filter
17. Separate the heated oxygen sensor (HO2S) connector.
MY
2002 Ford Focus LX
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Fig. 180: Separating Heated Oxygen Sensor (HO2S) Connector
18. Disconnect the radiator fan plug.

Separate the cable ties.
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2002 Ford Focus LX
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Fig. 181: Disconnecting Radiator Fan Plug
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2002 Ford Focus LX
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20. Disconnect the ground strap from the engine lifting eye.
21. Pull off the generator connector.
MY
2002 Ford Focus LX
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Fig. 183: Disconnecting Generator Connector
WARNING: Escaping brake fluid. Do not allow brake fluid to come

into contact with the skin or eyes. If brake fluid should
come into contact with your skin or eyes, rinse the
affected area immediately with water.
CAUTION: If any brake fluid gets on the paintwork wash it off

immediately with water.
22. Detach the high-pressure pipe from the clutch slave cylinder.
Pull out the clip.
Pull out the high-pressure pipe and tie it up with cable ties.
MY
2002 Ford Focus LX
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Fig. 184: Removing High-Pressure Pipe From Clutch Slave Cylinder
23. Separate the harness connector.
MY
2002 Ford Focus LX
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Fig. 185: Separating Harness Connector

25. Disconnect the plug of the vehicle speed sensor (VSS)
MY
2002 Ford Focus LX
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Fig. 186: Disconnecting Plug Of Vehicle Speed Sensor (VSS)
26. Disconnect the plug for the reversing lamp switch and the crankshaft position sensor (CKP
sensor).
Unclip the wiring loom from the engine.
MY
2002 Ford Focus LX
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Fig. 187: Disconnecting Plug For Reversing Lamp Switch And Crankshaft
Position Sensor (CKP Sensor)
27. Remove the air deflector and the radiator fan.

Undo the clips on both sides (left side shown).
Unhook the air deflector upwards and remove it downwards.
MY
2002 Ford Focus LX
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Fig. 188: Removing Air Deflector And Radiator Fan
28. Partially lower the vehicle.

29. Pull off the low pressure hoses.
MY
2002 Ford Focus LX
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Fig. 189: Removing Low Pressure Hoses
30. Detach the brake servo vacuum hose.
MY
2002 Ford Focus LX
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Fig. 190: Removing Brake Servo Vacuum Hose

working with fuel.
31. Detach the fuel pipes.

Detach the ground cable.
MY
2002 Ford Focus LX
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Fig. 191: Removing Fuel Pipes
32. Detach the coolant hoses.
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2002 Ford Focus LX
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Fig. 192: Removing Coolant Hoses
33. Detach the shift cable and selector cable from the transmission.
1. Detach the shift cable from the gear lever.
2. Pretension the abutment collars by turning them in an anti-clockwise direction and
remove the cable assembly from the bracket.
3. Detach the selector cable from the selector lever.
4. Pretension the abutment collars by turning them in an anti-clockwise direction and
remove the cable assembly from the bracket.
5. Undo the adjustment mechanism by pressing it in.
MY
2002 Ford Focus LX
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Fig. 193: Removing Shift Cable And Selector Cable From Transmission

35. Remove the drive belt cover.
MY
2002 Ford Focus LX
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Fig. 194: Removing Drive Belt Cover
36. Disconnect the power steering pressure switch (PSPS), slacken the drive belt and remove it
(vehicle without air conditioning shown).
Turn the belt tensioner clockwise.
MY
2002 Ford Focus LX
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Fig. 195: Disconnecting Power Steering Pressure Switch (PSPS) And Removing
Drive Belt
Vehicles with air conditioning
37. Detach the air conditioning compressor and tie it up on the radiator crossmember.
MY
2002 Ford Focus LX
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Fig. 196: Removing Air Conditioning Compressor
All vehicles
38. Detach the coolant hose and remove the power steering pump bolts.
MY
2002 Ford Focus LX
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Fig. 197: Removing Coolant Hose And Power Steering Pump Bolts

40. Detach the coolant expansion tank and position it to one side.
MY
2002 Ford Focus LX
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Fig. 198: Removing Coolant Expansion Tank
41. Remove the PAS reservoir and position it to one side.
MY
2002 Ford Focus LX
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Fig. 199: Removing PAS Reservoir
42. Detach the bracket of the power steering high-pressure pipe.
MY
2002 Ford Focus LX
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Fig. 200: Removing Bracket Of Power Steering High-Pressure Pipe
43. Detach the power steering pump and tie it up with cable ties.
MY
2002 Ford Focus LX
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Fig. 201: Removing Power Steering Pump

45. Remove the flexible exhaust pipe.
MY
2002 Ford Focus LX
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Fig. 202: Removing Flexible Exhaust Pipe
46. Remove the engine roll restrictor.
MY
2002 Ford Focus LX
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Fig. 203: Removing Engine Roll Restrictor
47. Detach both suspension arms (left-hand side shown).

1. Remove the bolt.
2. Detach the lower arm ball joint.
MY
2002 Ford Focus LX
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Fig. 204: Removing Lower Arm Ball Joint And Suspension Arms
CAUTION: The inner joint must not be bent at more than 18 degrees;
the outer joint must not be bent at more than 45 degrees.
48. Detach the right-hand front drive halfshaft with intermediate shaft.
Detach the intermediate shaft bearing cap.
Discard the nuts and bearing cap.
Pull the intermediate shaft with front drive halfshaft from the transmission and tie up
with cable ties.
Close off the transmission with auxiliary plugs.
MY
2002 Ford Focus LX
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Fig. 205: Removing Right-Hand Front Drive Halfshaft With Intermediate
Shaft
49. Detach the left-hand front drive halfshaft from the transmission using the special tool.
Pull out the front drive halfshaft and tie up with cable ties.
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2002 Ford Focus LX
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Fig. 206: Removing Left-Hand Front Drive Halfshaft From Transmission
Using Special Tool
50. Put the assembly table with wooden blocks on it under the vehicle.
51. Carefully lower the vehicle until the engine and transmission assembly is positioned on the
assembly stand.
52. Secure the engine and transmission assembly to the assembly stand with a retaining strap.
MY
2002 Ford Focus LX
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Fig. 207: Securing Engine And Transmission Assembly To Assembly Stand With
Retaining Strap
53. Remove the engine rear mounting.
MY
2002 Ford Focus LX
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Fig. 208: Removing Engine Rear Mounting
54. Remove the engine front mounting.
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2002 Ford Focus LX
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Fig. 209: Removing Engine Front Mounting
55. Carefully raise the vehicle.

Pull forwards the assembly stand with the engine and transmission assembly.
56. Hook the engine and transmission assembly into the crane.
MY
2002 Ford Focus LX
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Fig. 210: Hooking Engine And Transmission Assembly Into Crane
57. Remove the starter motor and ground cable.
MY
2002 Ford Focus LX
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Fig. 211: Removing Starter Motor And Ground Cable
58. Remove the flange bolts.
MY
2002 Ford Focus LX
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Fig. 212: Removing Flange Bolts (1 Of 2)
59. Remove the flange bolts (continued).
MY
2002 Ford Focus LX
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60. Separate the engine from the transaxle.
ENGINE - VEHICLES WITH: AUTOMATIC TRANSAXLE
Special Tool(s)
MY
2002 Ford Focus LX
cardiagn.com
Material
Cable ties
Removal
All Vehicles
MY
2002 Ford Focus LX
1. General remarks.
If necessary, separate the cable ties and install new on installation.
PRESSURE RELEASE .
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to do so can result in injury.
3. Open the coolant expansion tank.
CAUTION: Disconnect the battery positive and negative cables.

Remove the battery.
4. Remove the battery tray and detach the ground cable.

1. Unclip and separate the connector.
2. Unclip the wiring harness.
3. Unscrew the bolts.
4. Detach the positive and negative cables.
MY
2002 Ford Focus LX
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Fig. 215: Removing Battery Tray And Ground Cable

1. Detach the plug of the mass air flow (MAF) sensor.
2. Detach the positive crankshaft ventilation (PCV) hose.
Remove the air cleaner housing from the rubber bushing.
MY
2002 Ford Focus LX
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Fig. 216: Removing Plug Of Mass Air Flow (MAF) Sensor
6. Detach the ground cable.
MY
2002 Ford Focus LX
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7. Detach the ground cable from the battery terminal.
NOTE: The resonator is a push fit in the bracket.
MY
2002 Ford Focus LX
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Fig. 218: Removing Air Cleaner Intake With Resonator
8. Remove the air cleaner intake with resonator.
9. Drain the coolant.

Screw the drain plug back in after draining.
MY
2002 Ford Focus LX
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Fig. 219: Installing Drain Plug After Draining
NOTE: Prevent the piston rod from turning, using an Allen key.
MY
2002 Ford Focus LX
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Fig. 220: Slackening Suspension Strut Nuts
10. Slacken the suspension strut nuts by five turns on both sides.
MY
2002 Ford Focus LX
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12. Detach the connectors of the EI coil and the radio interference filter.
MY
2002 Ford Focus LX
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Fig. 222: Removing Connectors Of EI Coil And Radio Interference Filter
13. Detach the heated oxygen sensor (HO2S) connector.
MY
2002 Ford Focus LX
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Fig. 223: Detaching Heated Oxygen Sensor (HO2S) Connector
14. Disconnect the radiator fan connector.

Separate the cable ties (if necessary).
MY
2002 Ford Focus LX
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Fig. 224: Disconnecting Radiator Fan Connector
MY
2002 Ford Focus LX
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16. Remove the ground cable.
MY
2002 Ford Focus LX
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17. Detach the generator connector.
MY
2002 Ford Focus LX
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Fig. 227: Removing Generator Connector
18. Disconnect the harness connector.
MY
2002 Ford Focus LX
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Fig. 228: Disconnecting Harness Connector
19. Remove the air deflector and the radiator fan.

Undo the clips on both sides (left side shown).
Unhook the air deflector upwards and remove it downwards.
MY
2002 Ford Focus LX
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Fig. 229: Removing Air Deflector
20. Detach the vacuum hoses.
MY
2002 Ford Focus LX
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Fig. 230: Removing Vacuum Hoses (1 Of 2)
21. Detach the vacuum hoses.
MY
2002 Ford Focus LX
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Fig. 231: Removing Vacuum Hoses (2 Of 2)
22. Detach the brake servo vacuum hose.
MY
2002 Ford Focus LX
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Fig. 232: Removing Brake Servo Vacuum Hose

working with fuel.
MY
2002 Ford Focus LX
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Fig. 233: Removing Fuel Pipes
23. Detach the fuel pipes.

24. Detach the coolant hoses.
MY
2002 Ford Focus LX
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Fig. 234: Removing Coolant Hoses
25. Disconnect the selector lever cable from the automatic transaxle selector lever assembly.
MY
2002 Ford Focus LX
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Fig. 235: Disconnecting Selector Lever Cable From Automatic Transaxle Selector
Lever Assembly
26. Remove the oil filler pipe/selector cable bracket.
MY
2002 Ford Focus LX
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Fig. 236: Removing Oil Filler Pipe/Selector Cable Bracket
CAUTION: Do not loosen the connecting fitting from the transaxle

housing.
NOTE: Mark the location.
MY
2002 Ford Focus LX
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Fig. 237: Detaching Oil Cooler Pipes From Transaxle
27. Detach the oil cooler pipes from the transaxle.

NOTE: Install the engine drain plug after draining.
29. Drain the engine oil.

30. Remove the drive belt cover.
MY
2002 Ford Focus LX
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Fig. 238: Removing Drive Belt Cover
31. Disconnect the power steering pressure switch (PSPS), slacken the drive belt and remove it
(vehicle without air conditioning shown).
MY
2002 Ford Focus LX
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Fig. 239: Disconnecting Power Steering Pressure Switch (PSPS) And Removing
Drive Belt
32. Detach the air conditioning compressor and tie it up on the radiator crossmember.
MY
2002 Ford Focus LX
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Fig. 240: Detaching Air Conditioning Compressor
All vehicles
33. Detach the coolant hose and remove the bolts of the power steering pump.
MY
2002 Ford Focus LX
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Fig. 241: Detaching Coolant Hose And Removing Bolts Of Power Steering Pump

35. Detach the bracket of the power steering high-pressure pipe.
MY
2002 Ford Focus LX
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Fig. 242: Detaching Bracket Of Power Steering High-Pressure Pipe
36. Detach the power steering pump and position it to one side and secure with cable ties.
MY
2002 Ford Focus LX
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Fig. 243: Detaching Power Steering Pump
37. Remove both front wheels and tires.

38. Remove the flexible exhaust pipe.
MY
2002 Ford Focus LX
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Fig. 244: Removing Flexible Exhaust Pipe
39. Remove the engine roll restrictor.
MY
2002 Ford Focus LX
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Fig. 245: Removing Engine Roll Restrictor
40. Detach both suspension arms (left-hand side shown).

1. Remove the bolt.
2. Detach the lower arm ball joint.
MY
2002 Ford Focus LX
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Fig. 246: Removing Lower Arm Ball Joint And Suspension Arms
41. Detach the right-hand front drive halfshaft with intermediate shaft.
Detach the intermediate shaft bearing cap.
Discard the nuts and bearing cap.
Pull the intermediate shaft with front drive halfshaft from the transmission and tie up
with cable ties.
MY
2002 Ford Focus LX
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Fig. 247: Detaching Right-Hand Front Drive Halfshaft With Intermediate
Shaft
42. Detach the left-hand front drive halfshaft from the transmission using the special tool.
Pull out the front drive halfshaft and tie up with cable ties.
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2002 Ford Focus LX
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Fig. 248: Detaching Left-Hand Front Drive Halfshaft From Transmission
Using Special Tool
43. Put the assembly table with wooden blocks on it under the vehicle.
44. Carefully lower the vehicle until the engine and transmission assembly is positioned on the
assembly stand.
45. Secure the engine and transmission assembly to the assembly stand with a retaining strap.
MY
2002 Ford Focus LX
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Fig. 249: Securing Engine And Transmission Assembly To Assembly Stand With
Retaining Strap
46. Remove the engine rear mounting.
MY
2002 Ford Focus LX
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Fig. 250: Removing Engine Rear Mounting
47. Remove the engine front mounting nuts (without coolant expansion tank shown).
MY
2002 Ford Focus LX
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Fig. 251: Removing Engine Front Mounting Nuts
48. Carefully raise the vehicle.

Pull the assembly stand forwards with the engine and transmission assembly.
49. Hook the engine and transmission assembly into the crane.
MY
2002 Ford Focus LX
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Fig. 252: Hooking Engine And Transmission Assembly Into Crane
50. Remove the starter motor and ground cable.
MY
2002 Ford Focus LX
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Fig. 253: Removing Starter Motor And Ground Cable
51. Remove the flange bolts.
MY
2002 Ford Focus LX
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52. Remove the flange bolts (continued).
MY
2002 Ford Focus LX
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53. Separate the engine from the transaxle.
DISASSEMBLY
ENGINE
Special Tool(s)
MY
2002 Ford Focus LX
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Disassembly
All vehicles
1. General remarks.
The engine remains hooked onto the workshop hoist until the assembly stand can be
attached.
If the engine is positioned on the assembly stand and needs to be temporarily unhooked
from the workshop hoist, then it must be secured with retaining straps.
Cut cable ties as necessary and install new during installation.
2. Detach the catalytic converter bracket.
MY
2002 Ford Focus LX
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Fig. 257: Detaching Catalytic Converter Bracket
3. Detach the catalytic converter.

2. Remove the EGR pipe.
3. Unscrew the bolt from the catalytic converter bracket.
MY
2002 Ford Focus LX
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Fig. 258: Detaching Catalytic Converter (1 Of 2)
4. Detach the catalytic converter (cont.).
MY
2002 Ford Focus LX
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Fig. 259: Detaching Catalytic Converter (2 Of 2)
5. Disconnect the multiplug from the oil pressure switch and the knock sensor (KS).
MY
2002 Ford Focus LX
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Fig. 260: Disconnecting Multiplug From Oil Pressure Switch And Knock Sensor
(KS)
6. Detach the generator.

1. Disconnect the positive cable.
2. Unscrew the bolt.
3. Loosen the bolt.
MY
2002 Ford Focus LX
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Fig. 261: Disconnecting Positive Cable And Detaching Generator
7. Detach the intake manifold.

Remove the five bolts and unscrew two nuts.
MY
2002 Ford Focus LX
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8. Detach the ancillary components on the intake side.

1. Generator mounting bracket
2. Oil filter
3. Knock sensor (KS)
4. Oil pressure switch
MY
2002 Ford Focus LX
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Fig. 263: Removing Ancillary Components (Intake Side)
9. Attach the engine to the assembly stand.

10. Detach the ancillary components on the exhaust side.
1. Bracket for power steering pump
2. Bracket for air conditioning compressor
MY
2002 Ford Focus LX
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Fig. 264: Removing Ancillary Components (Exhaust Side)
11. Disconnect the positive crankcase ventilation.
MY
2002 Ford Focus LX
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Fig. 265: Disconnecting Positive Crankcase Ventilation
12. Detach the timing belt cover.

1. Water pump belt pulley
2. Drive belt idler pulley
3. Center timing belt cover/front engine mounting bracket
4. Upper timing belt cover
NOTE: Immobilize the flywheel using Special Tool 303-103.
5. Detach the pulley/vibration damper from the crankshaft.

6. Lower timing belt cover
MY
2002 Ford Focus LX
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MY
2002 Ford Focus LX
Fig. 266: Removing Timing Belt Cover

CAUTION: Do not pull the spark plug connectors by the wire when
removing them. If necessary pull off the ignition cables
from the ignition coils to prevent kinking the cables.
Slightly twist the spark plug connectors before removing
them in order to loosen the seals.
plugs.
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13. Detach the cylinder head cover.
Pull off the spark plug connectors.
2. Remove the bolts.

3. Remove the spark plugs.
MY
2002 Ford Focus LX
Fig. 267: Detaching Cylinder Head Cover

14. Detach the timing belt drive and the water pump.
1. Slacken the timing belt tensioner by twisting it counterclockwise and detach it.
2. Remove the timing belt.
3. Detach the upper idler pulley.
4. Detach the water pump.
5. Detach the crankshaft timing pulley and the thrust washer.
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2002 Ford Focus LX
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MY
2002 Ford Focus LX
Fig. 268: Detaching Timing Belt Drive And Water Pump

15. Detach the camshaft timing pulleys.

Use the special tool to stop them turning.
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Fig. 269: Removing Camshaft Timing Pulleys
NOTE: Working in several stages, evenly loosen each bolt two turns at
a time in the indicated sequence and remove the bolts.
16. Detach the camshaft bearing caps.

Take out the camshafts.
Remove the valve tappets and lay them in order to one side.
MY
2002 Ford Focus LX
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CAUTION: Center-punch the bolts once or twice to mark them for re-
use. The bolts can be re-used twice. Discard the bolts as
necessary.
CAUTION: The cylinder head must cool down to room temperature

before proceeding.
MY
2002 Ford Focus LX
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Fig. 271: Identifying Loosening Sequence Of Cylinder Head Bolts
17. Remove the cylinder head bolts.

18. Lift off the cylinder head.
Hook the workshop hoist onto the engine lifting eyes, lift off the cylinder head and
place it down onto clean blocks of wood.
Vehicles with manual transmission
19. Detach the clutch pressure plate and the clutch disc.
MY
2002 Ford Focus LX
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Fig. 272: Detaching Clutch Pressure Plate And Clutch Disc
All vehicles
20. Detach the flywheel.

Detach the special tool.
MY
2002 Ford Focus LX
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Fig. 273: Removing Flywheel
21. Remove the oil pan bolts.
MY
2002 Ford Focus LX
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Fig. 274: Removing Oil Pan Bolts
CAUTION: Do not damage the mating faces.
22. Remove the oil pan (shown with engine removed).

Separate the oil pan from the lower crankcase using a sharp spatula. Release the oil
pan from the lower crankcase by tapping slightly against the tightened drain plug with
a rubber hammer.
MY
2002 Ford Focus LX
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Fig. 275: Separating Oil Pan From Lower Crankcase
23. Detach the oil intake pipe and the lower crankcase.
1. Oil intake pipe bolts
2. Lower crankcase bolts
MY
2002 Ford Focus LX
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Fig. 276: Removing Oil Intake Pipe And Lower Crankcase
24. Detach the oil pump.
MY
2002 Ford Focus LX
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Fig. 277: Removing Oil Pump
25. Detach the crankshaft rear oil seal carrier and the crankshaft position (CKP) sensor together
with its bracket.
MY
2002 Ford Focus LX
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Fig. 278: Removing Crankshaft Rear Oil Seal Carrier And Crankshaft Position
(CKP) Sensor
NOTE: Lay all parts in order to one side.
26. Remove the crankshaft and pistons.

1. Detach the connecting rod bearing caps.
2. Detach the main bearing caps.
3. Take out the crankshaft and press out the pistons with the connecting rods.
MY
2002 Ford Focus LX
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Fig. 279: Removing Connecting Rod Bearing Caps Bolts
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

CYLINDER HEAD
Special Tool(s)
MY
2002 Ford Focus LX
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Material
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2002 Ford Focus LX
Disassembly
1. Remove the camshaft position sensor.
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Fig. 281: Removing Camshaft Position Sensor
2. Remove the electronic ignition (EI) coil pack.
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2002 Ford Focus LX
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Fig. 282: Removing Electronic Ignition (EI) Coil Pack
3. Remove the intake manifold.
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2002 Ford Focus LX
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4. Remove the exhaust manifold.
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Fig. 284: Removing Exhaust Manifold
5. Remove the timing belt tensioner and idler pulley.

1. Timing belt tensioner
2. Idler pulley
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2002 Ford Focus LX
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Fig. 285: Removing Timing Belt Tensioner And Idler Pulley
6. Remove the timing belt inner cover.
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2002 Ford Focus LX
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Fig. 286: Removing Timing Belt Inner Cover
7. Remove the bracket.
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2002 Ford Focus LX
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Fig. 287: Removing Bracket
8. Remove the rear lifting eye.
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2002 Ford Focus LX
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Fig. 288: Removing Rear Lifting Eye
9. Remove the front lifting eye.
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2002 Ford Focus LX
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Fig. 289: Removing Front Lifting Eye
10. Remove the cylinder head temperature (CHT) sensor.
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2002 Ford Focus LX
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Fig. 290: Removing Cylinder Head Temperature (CHT) Sensor
11. Using the special tools, compress the valve spring and remove the valve spring retainer keys,
the valve spring retainers, and the valve springs.
Remove the special tools.
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2002 Ford Focus LX
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Fig. 291: Removing Valve Spring Retainer Keys, Valve Spring Retainers And
Valve Springs
12. Inspect the valve spring, valve spring retainer and valve spring retainer key. For additional
information, refer to ENGINE SYSTEM-GENERAL INFORMATION . Install new parts
as necessary.
NOTE: Mark each valve if the original valves are to be used.
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2002 Ford Focus LX
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Fig. 292: Removing Valves
13. Remove the valves.

14. Using the special tools, remove and discard the valve stem seals.
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2002 Ford Focus LX
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15. Inspect the valves. For additional information refer to ENGINE SYSTEM-GENERAL
INFORMATION . Install new parts as necessary.
Assembly
NOTE: If installing the original valves, make sure the valves are
installed in the position from which they were removed. Coat
the valve stems with Super Premium SAE 5W-20 Motor Oil or
equivalent meeting Ford specification WSS-M2C153-H.
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2002 Ford Focus LX
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Fig. 294: Installing Valves
1. Install the valves.
NOTE: Use the seal protector provided with the replacement kit to
prevent damage to the valve stem seals.
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2002 Ford Focus LX
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Fig. 295: Installing Valve Stem Seals Onto Cylinder Head Valve Guides
2. Lubricate valve and guides with Super Premium SAE 5W-20 Motor Oil or equivalent
meeting Ford specification WSS-M2C153-H and using the special tool install the valve stem
seals onto the cylinder head valve guides.
3. Place the valve spring in position over the valve and install the valve spring retainer.
4. Using the special tools, compress the valve spring and install the valve spring retainer keys.
Remove the special tools.
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Fig. 296: Installing Valve Spring Retainer Keys And Valve Springs
5. Install the CHT sensor.
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Fig. 297: Installing CHT Sensor
6. Install the front lifting eye.
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Fig. 298: Installing Front Lifting Eye
7. Install the rear lifting eye.
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Fig. 299: Installing Rear Lifting Eye
8. Install the bracket.
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2002 Ford Focus LX
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Fig. 300: Installing Bracket
9. Install the timing belt inner cover.
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2002 Ford Focus LX
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Fig. 301: Installing Timing Belt Inner Cover
NOTE: Do not tighten the timing belt tensioner retaining bolt at this
stage.
10. Install the timing belt tensioner and the idler pulley.
1. Timing belt tensioner.
2. Idler pulley
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2002 Ford Focus LX
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Fig. 302: Installing Timing Belt Tensioner And Idler Pulley
11. Install the exhaust manifold.
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2002 Ford Focus LX
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Fig. 303: Installing Exhaust Manifold
12. Install the intake manifold.
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2002 Ford Focus LX
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13. Install the electronic ignition (EI) coil pack.
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2002 Ford Focus LX
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Fig. 305: Installing Electronic Ignition (EI) Coil Pack
14. Install the camshaft position sensor.
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2002 Ford Focus LX
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Fig. 306: Installing Camshaft Position Sensor
ASSEMBLY
ENGINE
Special Tool(s)
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2002 Ford Focus LX
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2002 Ford Focus LX

Material
High-temperature grease ESD-M1C220-A
Sealant remover WSKM2G348-A4
Sealant, joins between cylinder block and oil pump/oil seal carrier WSKM4G320-A
Gasket maker WSKM2G348-A5
Sealant, oil pan WSSM4G323-A7
Engine oil WSSM2C153-H
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Silicone grease, spark plug connector seals A696-M1C171-AA
Assembly
CAUTION: Do not damage the cylinder liner.
1. Preparatory operations.
2. Remove the carbon deposits at the upper edge of the cylinder.
3. Using a scraper and sealant remover, clean all re-usable parts and check them for damage.
4. Thoroughly clean all threaded bores.
5. Available sizes of main bearing shell.
NOTE: The main bearing shells are color coded.
Size A: 2.145 - 2.152 mm (green)

Size B: 2.142 - 2.147 mm (brown)
Size C: 2.135 - 2.142 mm (brown)
Size D: 2.130 - 2.137 mm (brown)
NOTE: Use main bearing shells of size "B" or "C" (refer to the
previous step).
6. Measure the radial clearance of the crankshaft. For additional information, refer to
ENGINE SYSTEM-GENERAL INFORMATION .
Select a bearing shell in accordance with the previous step to determine bearing
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2002 Ford Focus LX
clearance of 0.020 - 0.040 mm

7. Measure the axial clearance of the crankshaft. For additional information, refer to ENGINE
8. Measure the radial clearance of the camshaft. For additional information, refer to ENGINE
9. Measure the axial clearance of the camshaft. For additional information, refer to ENGINE
10. Measure the crankshaft. For additional information, refer to ENGINE SYSTEM-
GENERAL INFORMATION .
11. Measure the camshaft. For additional information, refer to ENGINE SYSTEM-GENERAL
INFORMATION .
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12. Measure the cylinder bore. For additional information, refer to ENGINE SYSTEM-
13. Measure the pistons. For additional information, refer to ENGINE SYSTEM-GENERAL
INFORMATION .
14. Measure the piston ring gaps. For additional information, refer to ENGINE SYSTEM-
15. Measure the axial play of the piston rings. For additional information, refer to ENGINE
16. Check the cylinder head distortion. For additional information, refer to ENGINE
17. Install the crankshaft.
Lay the main bearing shells clean and free of oil into the cylinder block and into the
bearing caps.
Coat the inner side of the bearing shells with engine oil.
3. Lay the crankshaft in place.

4. Do not tighten the main bearing cap bolts yet.
Attach the main bearing caps.
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2002 Ford Focus LX
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Fig. 308: Installing Main Bearing Caps
NOTE: The connecting rods are numbered starting at the timing belt
end. The joined valve recesses on the piston crown face the
intake side.
18. Install the pistons.

Coat the pistons and cylinder liners with engine oil.
Distribute the piston ring gaps and the elements of the oil scraper ring evenly around
the circumference (120 degrees).
Compress the piston rings using a piston ring compressor.
Press pistons 1 and 4 with the handle of a hammer into the cylinders. The connecting
rod bearing journals for cylinders 1 and 4 must be at BDC.
Lay the corresponding bearing shells clean and free of oil into the connecting rod and
the connecting rod bearing cap.
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NOTE: Use new connecting rod bearing cap bolts.
NOTE: Do not tighten the connecting rod bearing cap bolts yet.
Attach the bearing caps.

Rotate the crankshaft through 180 degrees and insert pistons 2 and 3.
Lay the corresponding bearing shells clean and free of oil into the connecting rod and
the connecting rod bearing cap.
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Fig. 309: Installing Pistons

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NOTE: The crankshaft must turn freely, if necessary check and adjust
the bearing clearances.
19. Tighten down the main bearings and connecting rod bearings.
1. Tighten the main bearing bolts in two stages.
Stage 1: 25 N.m
Stage 2: 60 degrees
4. Tighten the connecting rod bearing bolts in two stages.

Stage 1: 35 N.m
Stage 2: 90 degrees
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Fig. 310: Identifying Tightening Sequence Of Main Bearings And

Connecting Rod Bearings Caps Bolts
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20. Install the rear oil seal carrier and the crankshaft position (CKP) sensor with its bracket.
Position a new oil seal carrier with a new seal in installation position and tighten the
bolts finger tight.
2. Align the oil seal carrier so that the mating face of the oil seal carrier is
between 0.3 and 0.8 mm below the cylinder block.
3. Tighten the bolts.
4. Install the CKP sensor bracket.
Fig. 311: Installing Rear Oil Seal Carrier And Crankshaft Position (CKP) cardiagn.com
Sensor
NOTE: Use three flywheel bolts.
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2002 Ford Focus LX
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Fig. 312: Installing Oil Seal
21. Using special tool, draw in the oil seal.

22. Align the oil pump.
Position the oil pump with a new gasket and tighten the bolts finger tight.
Align the oil pump on both sides so that the sealing surfaces are 0.3 - 0.8 mm below
the cylinder block.
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2002 Ford Focus LX
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Fig. 313: Aligning Oil Pump On Both Sides
23. Install the oil pump with a new crankshaft front oil seal.
Check the alignment as described in the previous step, and correct if necessary.
Tighten the bolts in two stages:
Stage 1: 6 N.m.
Stage 2: 45 degrees.
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2002 Ford Focus LX
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Fig. 314: Installing Oil Pump With New Crankshaft Front Oil Seal
NOTE: Install the lower crankcase within 10 minutes of applying the

sealer.
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2002 Ford Focus LX
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Fig. 315: Applying Bead Of Sealer To Cylinder Block
24. Apply a 4 mm bead of sealer to the areas as shown.
NOTE: If the permissible amounts for protrusion or gap are exceeded,

install shims as described in the following steps.
25. Align the lower crankcase.

Position the lower crankcase with a new gasket and tighten the bolts finger tight.
Align the lower crankcase using a steel straight edge so that the cylinder block and the
lower crankcase are level, or at least do not exceed the following tolerances:
MTX 75 manual transaxle: 0.10 mm protrusion to 0.25 mm gap.
FN automatic transaxle: 0.00 mm to 0.25 mm gap.
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Fig. 316: Aligning Lower Crankcase Using Steel Straight Edge
26. Install lower crankcase spacer washers as necessary.

With a gap of 0.26 - 0.50 mm, fit 0.25 mm spacer washers.
With a gap of 0.51 - 0.75 mm, fit 0.50 mm spacer washers.
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Fig. 317: Installing Lower Crankcase Spacer Washers
27. Attach the lower crankcase and the oil intake pipe using a new gasket.
1. Tighten the bolts and check the alignment as described in the previous step, correct as
necessary.
2. Oil intake pipe bolts
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Fig. 318: Installing Lower Crankcase And Oil Intake Pipe Using New Gasket
CAUTION: Use studs. Sealant in the dead end bores can cause
damage to the ladder frame.
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Fig. 319: Installing Studs
28. Install 10 studs, M6 x 20, in the shown dead end bores.

29. Clean off any residues of oil or oil sludge from the oil pan.
NOTE: The sealing surfaces must be free of oil and sealant residue.
NOTE: Attach the oil pan within 10 minutes of applying the sealant.
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2002 Ford Focus LX
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Fig. 320: Applying 3 mm Bead Of Sealant To Oil Pan Flange
30. Apply a 3 mm bead of sealant to the oil pan flange.
NOTE: Do not remove the oil pan, after the first contact with the ladder
frame.
NOTE: Tightening sequence.
31. Attach the oil pan and tighten the bolts in two stages.
Stage 1: 6 N.m
Stage 2: 10 N.m
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2002 Ford Focus LX
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Fig. 321: Identifying Tightening Sequence Of Oil Pan Bolts
NOTE: Use new bolts.
NOTE: Remove any residual thread-locking compound from the

threaded bores.
32. Install the flywheel.

Attach the special tool and tighten the bolts.
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2002 Ford Focus LX
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Fig. 322: Installing Flywheel
NOTE: Apply high-temperature grease thinly enough to make sure that

no grease emerges from the splines when the clutch disc is
slid onto the transmission input shaft.
33. Evenly coat the splines of the clutch disc with high-temperature grease.
NOTE: Center the clutch disk on the pressure plate.
34. Install the clutch.

1. Position the clutch pressure plate with the centered clutch disc.
2. Working diagonally in several stages, tighten the bolts one turn at a time.
3. Check the centering and correct as necessary.
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2002 Ford Focus LX
Detach the special tool.
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Fig. 323: Installing Clutch
35. Make two guide studs as shown.
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2002 Ford Focus LX
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Fig. 324: Identifying Stud
36. Lay a new cylinder head gasket on the cylinder block.

1. Lay a new cylinder head gasket in place.
2. Screw in the guide studs made in the previous step.
3. Check that the alignment dowels are correctly seated.
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2002 Ford Focus LX
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Fig. 325: Installing New Cylinder Head Gasket On Cylinder Block
37. Put the cylinder head in place.

Hook the cylinder head into the workshop hoist by the engine lifting eyes and move it
into position.
CAUTION: Do not re-tighten the cylinder head bolts.
NOTE: Screw in the cylinder head bolts free of oil.
NOTE: Tighten the cylinder head bolts in three stages in the indicated
sequence.
38. Attach the cylinder head.

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2002 Ford Focus LX
Stage 1: 20 N.m
Stage 2: 40 N.m
Stage 3: 90 degrees
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Fig. 326: Identifying Tightening Sequence Of Cylinder Head Bolts
39. Lubricate the valve tappets with engine oil and fit them in the correct order.
NOTE: The identification numbers are located on the outside of the

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2002 Ford Focus LX
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Fig. 327: Applying Thin Coat Of Gasket Maker To Marked Areas On Camshaft
Bearing Caps
40. Apply a thin coat of gasket maker to the marked areas on camshaft bearing caps 0 and 5.
41. Turn the crankshaft to approximately 60 degrees BTDC.
NOTE: Lay the camshafts in place with none of the cams at full lift.
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Fig. 328: Coating Camshafts And Camshaft Bearing Caps With Engine Oil
42. Coat the camshafts and camshaft bearing caps with engine oil and insert them.
NOTE: Working in several stages, evenly screw in the camshaft

bearing cap bolts in the indicated sequence, half a turn at a
time, and then tighten them down in two stages.
43. Tighten the camshaft bearing caps.

Stage 1: 10 N.m
Stage 2: 19 N.m
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Fig. 329: Identifying Tightening Sequence Of Camshaft Bearing Caps Bolts
Valve Clearance .
Lubricate the camshaft and the seal lip of the oil seal with engine oil.
Draw in the new oil seals using the special tool, a washer and an M10 x 70 bolt.
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2002 Ford Focus LX
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46. Turn the crankshaft to TDC on cylinder number 1.
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Fig. 331: Turning Crankshaft For Positioning Cylinder Number 1 To TDC Position
NOTE: Cylinders 1 and 4 are at TDC when the Woodruff key points
towards the piston.
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Fig. 332: Removing Blanking Plug
47. Remove the blanking plug and align the crankshaft at TDC using the special tool.
48. Turn the camshafts to ignition point on cylinder number 1 and insert the special tool into the
camshafts.
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Fig. 333: Inserting Special Tool Into Camshafts
NOTE: Do not tighten the bolts. It must be possible to turn the timing
pulleys on the camshafts.
49. Slide the timing pulleys onto the camshafts and screw in the bolts.
50. Install a new gasket into the water pump.
1. Lay the gasket in place.
2. Secure the gasket by bending over the tabs.
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Fig. 334: Installing New Gasket Into Water Pump
CAUTION: Do not kink the timing belt (do not bend the timing belt
less than a diameter of 35mm).
CAUTION: Do not rotate the crankshaft; as necessary check that it is

still resting against the timing pin.
NOTE: The lug of the timing belt tensioner must not be hooked into the
sheet metal cover during timing belt installation.
51. Position a new timing belt in place.

1. Slide the crankshaft timing pulley with a thrust washer onto the crankshaft.
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2002 Ford Focus LX
2. Attach the water pump.

3. Attach the upper idler pulley.
4. Starting from the crankshaft timing belt pulley and working counterclockwise, position
the timing belt in place while keeping it under tension.
5. Attach the timing belt tensioner and screw in the bolt five turns.
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2002 Ford Focus LX
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Fig. 335: Installing New Timing Belt

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2002 Ford Focus LX
CAUTION: Incorrect timing belt tension will cause incorrect valve

timing.
52. Pre tension the timing belt.

1. Rotate the tensioner locating tab counterclockwise and insert the locating tab into the
slot in the rear timing cover.
2. Position the hex key slot in the tensioner adjusting washer to the 4 o'clock position.
3. Tighten the attaching bold enough to seat the tensioner firmly against the rear timing
cover, but still allow the tensioner adjusting washer to be rotated using a 6mm hex key.
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Fig. 336: Tightening Attaching Bold For Seating Tensioner Firmly Against
Rear Timing Cover
CAUTION: Tension the timing belt, working counterclockwise.

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2002 Ford Focus LX
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Fig. 337: Rotating Adjusting Washer Counterclockwise Until Notch In Pointer
Centered Over Index Line On Locating Tab
53. Using the hex key, rotate the adjusting washer counterclockwise until the notch in the
pointer is centered over the index line on the locating tab (the pointer will move clockwise
during adjustment).
54. While holding the adjusting washer in position, tighten the bolt.
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2002 Ford Focus LX
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Fig. 338: Tightening Bolt
CAUTION: Do not tighten against Special Tool 303-465.
NOTE: Use the special tool to hold the timing pulleys.
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2002 Ford Focus LX
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Fig. 339: Tightening Timing Pulleys Bolts
55. Tighten the bolts on the timing pulleys.

56. Unscrew and remove Special Tool 303-574.
57. Take Special Tool 303-465 off the camshafts.
NOTE: Turn the engine two turns in the normal direction of rotation by
the crankshaft.
58. Check the valve timing by inserting the special tools and correct the alignment as necessary.
Screw in Special Tool 303-574 and make sure that the crankshaft is resting against the
special tool.
Insert Special Tool 303-465 into the camshafts. If necessary loosen the timing pulleys
and correct the camshaft alignment.
Detach the special tools.
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2002 Ford Focus LX
59. Install the blanking plug.
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Fig. 340: Installing Blanking Plug

silicone grease to avoid damaging the spark plug
connectors.

NOTE: Coat the inside of the spark plug connector to a depth of 5 - 10

mm with silicone grease.
60. Install the cylinder head cover and the spark plugs.
1. Screw in the spark plugs.
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2. Tighten the cylinder head cover bolts in two stages.

Stage 1: 2 N.m
Stage 2: 7 N.m
Push on the spark plug connectors until they click in place.
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Fig. 341: Installing Cylinder Head Cover
NOTE: Check the seating of the gasket on the upper timing belt cover
and correct as necessary.
61. Attach the timing belt covers and the belt pulleys.
1. Lower timing belt cover
2. Crankshaft pulley/vibration damper
3. Upper timing belt cover
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4. Center timing belt cover/front engine mounting bracket

5. Drive belt idler pulley
6. Water pump belt pulley
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Fig. 342: Installing Timing Belt Covers And Belt Pulleys

62. Connect the positive crankcase ventilation using a new seal.

1. Three bolts
2. One bolt
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Fig. 343: Connecting Positive Crankcase Ventilation Using New Seal
63. Attach the ancillary components on the exhaust side.

1. Bracket for air conditioning compressor.
2. Bracket for power steering pump to cylinder head.
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2002 Ford Focus LX
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Fig. 344: Installing Ancillary Components Of Exhaust Side
3. Bracket for power steering pump to cylinder block.

64. Hook the engine by the engine lifting eyes onto the workshop hoist and detach it from the
assembly stand.
Put the engine down onto the assembly stand and leave it hooked onto the workshop
hoist.
NOTE: Coat the oil filter seal with engine oil.
65. Attach the ancillary components on the intake side.

1. Oil pressure switch
2. KS
3. Attach a new oil filter.
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2002 Ford Focus LX
4. Generator bracket to cylinder block

5. Generator bracket to cylinder head
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Fig. 345: Installing Ancillary Components Of Intake Side
66. Attach the intake manifold.

Screw in five bolts and fit two nuts.
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67. Attach the exhaust manifold to the cylinder head using the alignment spacers with the two
outside bolts and a new manifold gasket.
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2002 Ford Focus LX
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Fig. 347: Installing Exhaust Manifold To Cylinder Head
CAUTION: Do not allow debris to fall into the exhaust manifold.
CAUTION: Always follow the correct installation sequence for the

catalytic converter in order to prevent damage.
CAUTION: Examine the seats and threads in the exhaust catalyst

cone and EGR valve. Clean as required.
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Fig. 348: Loosening Bracket Of Catalytic Converter
68. Loosen the bracket for the catalytic converter so that it can move freely.
NOTE: Use a new gasket.
NOTE: Do not fully tighten the nuts/bolts at this stage.
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Fig. 349: Installing Catalytic Converter On Exhaust Manifold
69. Position the catalytic converter on the exhaust manifold using new hardware.
71. Using a nut and bolt, temporarily secure the catalytic converter to the bracket at the rear.
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Fig. 350: Securing Catalytic Converter To Bracket At Rear
72. Tighten the catalytic converter to the exhaust manifold.
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2002 Ford Focus LX
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Fig. 351: Tightening Catalytic Converter To Exhaust Manifold
NOTE: Always use a new catalyst to EGR valve pipe assembly.
NOTE: Loosely assemble the pipe to both the EGR valve and the
exhaust catalyst before tightening the unions.
73. Attach the catalytic converter.

1. Tighten the bolts on the catalytic converter bracket.
2. Install a new EGR-pipe.
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2002 Ford Focus LX
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Fig. 352: Installing Catalytic Converter
74. Attach the bracket for the catalytic converter.

Tighten the bolts.
Remove the temporary bolt from the rear catalytic converter bracket.
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2002 Ford Focus LX
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Fig. 353: Installing Bracket Of Catalytic Converter
75. Attach the generator.

1. Screw in and tighten the bolt.
2. Tighten the bolt.
3. Connect the positive cable.
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2002 Ford Focus LX
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Fig. 354: Installing Generator And Positive Cable
76. Connect the multiplug to the oil pressure switch and the KS.
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2002 Ford Focus LX
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Fig. 355: Connecting Multiplug To Oil Pressure Switch And KS
INSTALLATION
ENGINE - VEHICLES WITH: MTX-75/MANUAL TRANSAXLE
Special Tool(s)
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2002 Ford Focus LX
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Material
Cable ties
Transmission fluid ESDM-2C186-A
Coolant ESD-M97B49 -A
Installation
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2002 Ford Focus LX
All vehicles
1. General note.
If necessary, use Special Tool 412-108 to install coolant and ventilation hoses.
Using a retaining strap, secure the transmission on the assembly stand.
Hook the engine into the crane, bring into position at the transmission and support
using wooden blocks.
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Fig. 357: Hooking Engine Into Crane, Bring Into Position At Transmission And
Support Using Wooden Blocks
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2002 Ford Focus LX
3. Install the flange bolts.
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Fig. 358: Installing Flange Bolts (1 Of 2)

Detach the crane from the engine.
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5. Install the starter motor and ground cable.
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Fig. 360: Installing Starter Motor And Ground Cable

7. Position the engine and transmission assembly on the assembly stand below the vehicle.
Carefully lower the vehicle.
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Fig. 361: Positioning Engine And Transmission Assembly On Assembly Stand
Below Vehicle
NOTE: Insert/screw on the bolts and nuts fingertight.
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2002 Ford Focus LX
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Fig. 362: Installing Front Engine Mounting
8. Install the front engine mounting.
NOTE: Screw on nuts fingertight.
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2002 Ford Focus LX
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Fig. 363: Installing Rear Engine Mounting
9. Install the rear engine mounting.

10. Remove the retaining strap from the transmission.
Remove the assembly stand.
12. Install the engine roll restrictor.
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Fig. 364: Installing Engine Roll Restrictor
CAUTION: The inner joint must not be bent at more than 18° the
outer joint must not be bent at more than 45°.
NOTE: Use new bolts and new center bearing caps.
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2002 Ford Focus LX
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Fig. 365: Installing Right-Hand Input Shaft With Intermediate Shaft
13. Attach the right-hand input shaft with intermediate shaft.
CAUTION: The inner joint must not be bent at more than 18° the
outer joint must not be bent at more than 45°.
NOTE: Use a new snap ring.
NOTE: Click the snap ring into place.
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Fig. 366: Installing Left-Hand Drive Shaft
14. Attach the left-hand drive shaft.

15. Attach both suspension lower arms (left-hand side shown).
1. Attach the lower arm ball joint.
2. Install the bolt.
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Fig. 367: Installing Suspension Lower Arms And Lower Arm Ball Joint
16. Install the flexible exhaust pipe.
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2002 Ford Focus LX
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Fig. 368: Installing Flexible Exhaust Pipe

18. Tighten the rear engine mounting nuts/bolts.
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2002 Ford Focus LX
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Fig. 369: Tightening Rear Engine Mounting Nuts/Bolts
19. Tighten the front engine mounting nuts.
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Fig. 370: Tightening Front Engine Mounting Nuts
20. Install the power steering pump and fit the upper bolts.
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Fig. 371: Installing Power Steering Pump
21. Attach the bracket to power steering high-pressure pipe.
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Fig. 372: Installing Bracket To Power Steering High-Pressure Pipe
22. Install the PAS reservoir.
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Fig. 373: Installing PAS Reservoir
23. Install the coolant expansion tank.
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2002 Ford Focus LX
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Fig. 374: Installing Coolant Expansion Tank

25. Attach the power steering pump lower bolts, power steering pump pressure switch electrical
connector and the radiator lower coolant hose.
1. Power steering pump lower bolts.
2. Power steering pump pressure switch electrical connector.
3. Radiator lower coolant hose.
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2002 Ford Focus LX
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Fig. 375: Installing Power Steering Pump Lower Bolts, Power Steering Pump
Pressure Switch Electrical Connector And Radiator Lower Coolant Hose
26. Attach the air conditioning compressor.
MY
2002 Ford Focus LX
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Fig. 376: Installing Air Conditioning Compressor
All Vehicles
27. Install and tension the drive belt and connect the power steering pressure switch (PSPS).
MY
2002 Ford Focus LX
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Fig. 377: Installing Drive Belt And Power Steering Pressure Switch (PSPS)
28. Install the drive belt cover.
MY
2002 Ford Focus LX
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NOTE: Screw on wheel nuts fingertight.
29. Install the front wheel.

NOTE: The adjusting mechanisms must be released by pressing them

in.
NOTE: The abutment brackets are tensioned automatically once they

have been released.
31. Connect the cables to the transaxle and adjust them.

1. Release the abutment bracket by turning it counterclockwise and install the cable in
the bracket.
MY
2002 Ford Focus LX
2. Connect the shift cable from the gear selector lever.

3. Release the abutment bracket by turning it counterclockwise and install the cable in
the bracket.
4. Connect the shift cable to the gearshift lever.
5. Lock the adjusting mechanism by pressing down the clips.
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Fig. 379: Connecting And Adjusting Shift Cable To Transaxle
32. Attach the coolant hoses (continued).
MY
2002 Ford Focus LX
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Fig. 380: Installing Coolant Hoses
33. Attach the fuel pipes.
MY
2002 Ford Focus LX
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Fig. 381: Installing Fuel Pipes
34. Attach the brake servo vacuum hose.
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2002 Ford Focus LX
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Fig. 382: Installing Brake Servo Vacuum Hose
35. Attach the vacuum hoses.
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2002 Ford Focus LX
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Fig. 383: Installing Vacuum Hoses
36. Install the air deflector and the radiator fan.

Hook the air deflector in place.
Install the clips on both sides (left side shown).
MY
2002 Ford Focus LX
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Fig. 384: Installing Air Deflector
37. Connect the plug for the reversing lamp switch and the crankshaft position sensor (CKP
sensor).
Clip on the wiring loom.
MY
2002 Ford Focus LX
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Fig. 385: Connecting Plug Of Reversing Lamp Switch And Crankshaft Position
Sensor (CKP Sensor)
38. Connect the plug to the vehicle speed sensor (VSS)
MY
2002 Ford Focus LX
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Fig. 386: Connecting Plug To Vehicle Speed Sensor (VSS)
39. Connect the harness connectors.
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2002 Ford Focus LX
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Fig. 387: Connecting Harness Connectors
WARNING: Escaping brake fluid. Do not allow brake fluid to come

into contact with the skin or eyes. If brake fluid should
come into contact with your skin or eyes, rinse the
affected area immediately with water.
CAUTION: If any brake fluid gets on the paintwork wash it off

immediately with water.
40. Attach the high-pressure pipe to the clutch slave cylinder.

Slide on the clip.
MY
2002 Ford Focus LX
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Fig. 388: Installing High-Pressure Pipe To Clutch Slave Cylinder
41. Attach the generator connector.
MY
2002 Ford Focus LX
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Fig. 389: Installing Generator Connector
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2002 Ford Focus LX
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43. Connect the radiator fan connector.

Install the cable ties.
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2002 Ford Focus LX
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Fig. 391: Connecting Radiator Fan Connector
44. Attach the heated oxygen sensor (HO2S) connector.
MY
2002 Ford Focus LX
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Fig. 392: Connecting Heated Oxygen Sensor (HO2S) Connector
45. Attach the connectors of the EI coil and the radio interference filter.
MY
2002 Ford Focus LX
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Fig. 393: Connecting Connectors Of EI Coil And Radio Interference Filter
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2002 Ford Focus LX
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47. Install the air cleaner intake with resonator.
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2002 Ford Focus LX
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Fig. 395: Installing Air Cleaner Intake With Resonator
48. Attach the ground cable.
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2002 Ford Focus LX
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Fig. 396: Installing Ground Cable


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2002 Ford Focus LX
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Fig. 397: Installing Mass Air Flow (MAF) Sensor Multiplug
NOTE: Stop it from turning using an Allen key.
50. Tighten the suspension strut nuts on the right and left.
Tighten by hand with a ring spanner.
Use a torque wrench to tighten to specification.
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2002 Ford Focus LX
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Fig. 398: Tightening Suspension Strut Nuts
51. Install the battery tray.

1. Attach the ground cable to the body.
2. Attach the battery positive and negative cables.
3. Install the bolts.
4. Clip the wiring harness in place.
5. Connect and clip in the plug.
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2002 Ford Focus LX
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Fig. 399: Installing Battery Tray
52. Tighten the wheel nuts.
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2002 Ford Focus LX
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Fig. 400: Tightening Wheel Nuts
53. Remove the special tool 308-437.
CAUTION: When the battery has been disconnected and

reconnected, some abnormal drive symptoms may occur
while the vehicle relearns its adaptive strategy. The
vehicle may need to be driven 16 km (10 miles) or more to
relearn the strategy.
54. Install and connect the battery.

55. Fill the cooling system. For additional information, refer to ENGINE COOLING .
56. Fill manual transmission fluid. For additional information, refer to DRAINING &
REFILLING article .
57. Fill the engine with engine oil.
MY
2002 Ford Focus LX
58. Check the routing of the vacuum hoses and wiring and secure them with cable ties.
59. Bleed the hydraulic clutch operating system. For additional information, refer to
BLEEDING HYDRAULIC SYSTEM article .
60. Check the fluid levels after the road test and correct as necessary.
61. Check the engine and cooling system for leaks (visual inspection).
ENGINE - VEHICLES WITH: AUTOMATIC TRANSAXLE
Special Tool(s)

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Material
Cable ties
MY
2002 Ford Focus LX
Automatic transmission fluid XT-5-QM (MERCON(R) V)

Coolant ESD-M97B49 -A
Installation
All vehicles
1. General note.
If necessary, use Special Tool 412 - 108 to install coolant and ventilation hoses.
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Using a retaining strap, secure the transmission on the assembly stand.
Hook the engine into the crane, bring into position at the transmission and support
using wooden blocks.
MY
2002 Ford Focus LX
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Fig. 402: Hooking Engine Into Crane, Bring Into Position At Transmission And
Support Using Wooden Blocks
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2002 Ford Focus LX
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Detach the crane from the engine.
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2002 Ford Focus LX
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5. Install the starter motor and ground cable.
MY
2002 Ford Focus LX
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Fig. 405: Installing Starter Motor And Ground Cable

7. Position the engine and transmission assembly on the assembly stand below the vehicle.
Carefully lower the vehicle.
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2002 Ford Focus LX
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Fig. 406: Positioning Engine And Transmission Assembly On Assembly Stand
Below Vehicle
NOTE: Do not fully tighten the bolts and nuts at this stage.
MY
2002 Ford Focus LX
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Fig. 407: Installing Engine Front Mounting
8. Install the engine front mounting.
NOTE: Do not fully tighten the nuts at this stage.
MY
2002 Ford Focus LX
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Fig. 408: Installing Engine Rear Mounting
9. Install the engine rear mounting.

10. Remove the retaining strap from the transmission.
Remove the assembly stand.
12. Install the engine roll restrictor.
MY
2002 Ford Focus LX
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Fig. 409: Installing Engine Roll Restrictor
CAUTION: The inner joint must not be bent at more than 18 ° ; the
outer joint must not be bent at more than 45 °.
NOTE: Use new bolts and new center bearing caps.
MY
2002 Ford Focus LX
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Fig. 410: Installing Right-Hand Input Shaft With Intermediate Shaft
13. Attach the right-hand input shaft with intermediate shaft.
CAUTION: The inner joint must not be bent at more than 18 ° ; the
outer joint must not be bent at more than 45 °.
NOTE: Use a new snap ring.
NOTE: Click the snap ring into place.
MY
2002 Ford Focus LX
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Fig. 411: Installing Left-Hand Drive Shaft
14. Attach the left-hand drive shaft.

15. Attach the both suspension lower arms (left-hand side shown).
1. Attach the lower arm ball joint.
2. Install the bolt.
MY
2002 Ford Focus LX
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Fig. 412: Installing Suspension Lower Arms
16. Install the flexible exhaust pipe.
MY
2002 Ford Focus LX
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Fig. 413: Installing Flexible Exhaust Pipe

18. Tighten the engine rear mounting nuts/bolts.
MY
2002 Ford Focus LX
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Fig. 414: Tightening Engine Rear Mounting Nuts
19. Tighten the engine front mounting nuts.
MY
2002 Ford Focus LX
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Fig. 415: Tightening Engine Front Mounting Nuts
20. Attach the power steering pump and install the upper bolts.
MY
2002 Ford Focus LX
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Fig. 416: Installing Power Steering Pump
21. Attach the bracket to power steering high-pressure pipe.
MY
2002 Ford Focus LX
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Fig. 417: Installing Bracket To Power Steering High-Pressure Pipe

23. Attach the power steering pump lower bolts, power steering pressure switch electrical
connector and the radiator lower coolant hose.
1. Power steering pump lower bolts.
2. Power steering pump pressure switch electrical connector.
3. Radiator lower coolant hose.
MY
2002 Ford Focus LX
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Fig. 418: Installing Power Steering Pump Lower Bolts, Power Steering Pressure
Switch Electrical Connector And Radiator Lower Coolant Hose
24. Attach the air conditioning compressor.
MY
2002 Ford Focus LX
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Fig. 419: Installing Air Conditioning Compressor
All Vehicles
25. Install and tension the drive belt and connect the power steering pressure switch (PSPS).
MY
2002 Ford Focus LX
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Fig. 420: Installing Drive Belt And Power Steering Pressure Switch (PSPS)
26. Install the drive belt cover.
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2002 Ford Focus LX
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27. Install both front wheels and tires.

28. Install the oil filler pipe/selector cable bracket.
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2002 Ford Focus LX
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Fig. 422: Installing Oil Filler Pipe/Selector Cable Bracket
29. Connect the selector lever cable to the automatic transaxle selector lever assembly.
MY
2002 Ford Focus LX
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Fig. 423: Connecting Selector Lever Cable To Automatic Transaxle Selector Lever
Assembly
30. Attach the oil cooler pipes to the transaxle.
MY
2002 Ford Focus LX
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Fig. 424: Installing Oil Cooler Pipes To Transaxle
31. Attach the coolant hoses (continued).
MY
2002 Ford Focus LX
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Fig. 425: Installing Coolant Hoses
32. Attach the fuel pipes.
MY
2002 Ford Focus LX
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Fig. 426: Installing Fuel Pipes
33. Attach the brake servo vacuum hose.
MY
2002 Ford Focus LX
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Fig. 427: Installing Brake Servo Vacuum Hose
MY
2002 Ford Focus LX
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Fig. 428: Installing Vacuum Hoses (1 Of 2)
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2002 Ford Focus LX
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Fig. 429: Installing Vacuum Hoses (2 Of 2)
36. Install the air deflector and the radiator fan.

Hook the air deflector in place.
Install the clips on both sides (left side shown).
MY
2002 Ford Focus LX
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Fig. 430: Installing Air Deflector
37. Connect the harness connectors.
MY
2002 Ford Focus LX
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Fig. 431: Connecting Harness Connectors
38. Attach the generator connector.
MY
2002 Ford Focus LX
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Fig. 432: Installing Generator Connector
39. Install the ground cable.
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2002 Ford Focus LX
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40. Connect the fuel injector cable ties.
MY
2002 Ford Focus LX
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Fig. 434: Connecting Fuel Injector Cable Ties
41. Connect the radiator fan connector.

Install the cable ties.
MY
2002 Ford Focus LX
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Fig. 435: Connecting Radiator Fan Connector
42. Attach the heated oxygen sensor (HO2S) connector.
MY
2002 Ford Focus LX
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Fig. 436: Installing Heated Oxygen Sensor (HO2S) Connector
43. Attach the connectors of the EI coil and the radio interference filter.
MY
2002 Ford Focus LX
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Fig. 437: Installing Connectors Of EI Coil And Radio Interference Filter
MY
2002 Ford Focus LX
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45. Install the air cleaner intake with resonator.
MY
2002 Ford Focus LX
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Fig. 439: Installing Air Cleaner Intake With Resonator
46. Attach the ground cable.
MY
2002 Ford Focus LX
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47. Attach the ground cable to the battery terminal.


MY
2002 Ford Focus LX
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Fig. 441: Installing Mass Air Flow (MAF) Sensor Multiplug
NOTE: Stop it from turning using an Allen key.
49. Tighten the suspension strut nuts on the right and left.
Tighten by hand with a ring spanner.
Use a torque wrench to tighten to specification.
MY
2002 Ford Focus LX
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Fig. 442: Tightening Suspension Strut Nuts
50. Install the battery tray.

1. Attach the ground cable to the body.
2. Attach the battery positive and negative cables.
3. Install the bolts.
4. Clip the wiring harness in place.
5. Connect and clip in the plug.
MY
2002 Ford Focus LX
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Fig. 443: Installing Battery Positive And Negative Cables And Tray
51. Install the battery.
CAUTION: When the battery has been disconnected and

reconnected, some abnormal drive symptoms may occur
while the vehicle relearns its adaptive strategy. The
vehicle may need to be driven 16 km (10 miles) or more to
relearn the strategy.
52. Install and connect the battery.

53. Fill the cooling system. For additional information, refer to ENGINE COOLING .
54. Fill automatic transmission fluid. For additional information, refer to AUTOMATIC
55. Fill the engine with engine oil.
MY
2002 Ford Focus LX
56. Check the routing of the vacuum hoses and wiring and secure them with cable ties.
57. Check the fluid levels after the road test and correct as necessary.
58. Check the engine and cooling system for leaks (visual inspection).
cardiagn.com
MY

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2002 Ford Focus LX

2002 ENGINE Engine - 2.0L Zetec-E (Zetec) - Focus

Engine - 2.0L Zetec-E (Zetec) - Focus

ENGINE 2.0L ZETEC-E (ZETEC) GENERAL DATA SPECIFICATION

ENGINE 2.0L ZETEC-E (ZETEC) ENGINE OIL SPECIFICATIONS

ENGINE 2.0L ZETEC-E (ZETEC) ENGINE OIL CAPACITIES SPECIFICATIONS

LUBRICANTS, FLUIDS, SEALERS AND ADHESIVES

ENGINE 2.0L ZETEC-E (ZETEC) LUBRICANTS, FLUID, SEALERS AND

ENGINE 2.0L ZETEC-E (ZETEC) CYLINDER BLOCK SPECIFICATIONS

ENGINE 2.0L ZETEC-E (ZETEC) PISTONS SPECIFICATIONS

ENGINE 2.0L ZETEC-E (ZETEC) CRANKSHAFT SPECIFICATIONS

LOWER CRANKSHAFT SPACER

ENGINE 2.0L ZETEC-E (ZETEC) LOWER CRANKSHAFT SPACER

ENGINE 2.0L ZETEC-E (ZETEC) CONNECTING ROD SPECIFICATIONS

ENGINE 2.0L ZETEC-E (ZETEC) CAMSHAFT SPECIFICATIONS

ENGINE 2.0L ZETEC-E (ZETEC) VALVES SPECIFICATIONS

Exhaust valve 0.017-0.064

ENGINE 2.0L ZETEC-E (ZETEC) CYLINDER HEAD SPECIFICATIONS

ENGINE 2.0L ZETEC-E (ZETEC) TORQUE SPECIFICATIONS

Oil drain plug, MTX transmission 45 33 -

Main bearing bolts (1) - -

DESCRIPTION AND OPERATION

Hydraulic engine mountings

Cast iron block

The changes made are:

VIN Derivative location on the cylinder block

Fig. 2: Identifying VIN Derivative Location On Cylinder Block

Central timing belt cover/front engine mounting bracket

Fig. 4: Identifying Engine Valve Train Components

Timing Belt Tensioner

CAUTION: Only tension the timing belt by turning in a counterclockwise

Fig. 6: Identifying Automatic Timing Belt Tensioner

Courtesy of FORD MOTOR CO.

View of Crankcase Reinforcements

Fig. 9: Identifying Crankcase Reinforcements

Powertrain Control Module (PCM)

The PCM controls:

DIAGNOSIS AND TESTING

REFER to ENGINE SYSTEM-GENERAL INFORMATION article .

CAUTION: Exchange the tappets to correct the valve clearance.

CAUTION: Disconnect the battery ground cable.

NOTE: Do not remove the upper timing belt cover.

1. Undo the bolts in the upper timing belt cover.

CAUTION: Do not pull the spark plug connectors by the ignition

NOTE: Loosening sequence: from the outside to the inside, working

2. Remove the cylinder head cover.

CAUTION: Only rotate the engine on the crankshaft and in its

3. Set the engine to TDC on cylinder number 1.

4. Measure the valve clearance using feeler gauges.

Permitted valve clearance: exhaust (0.27 - 0.34 mm)

CAUTION: Only rotate the engine on the crankshaft.

5. Measure the valve clearance (continued).

0.15 mm; exhaust 0.30 mm)

6. Remove the camshafts. For additional information, refer to CAMSHAFT .

NOTE: The number on the tappet indicates the tappet thickness.

7. Determine the tappet thickness required.

Inlet valves: tappet thickness required = thickness of currently installed tappet +

CAUTION: Set the piston on cylinder number 1 to approximately 25

NOTE: Turn the camshaft to measure the valve clearance.