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Section 1326 (Engine - SVT): Disassembly: Engine

WARNING: This page is about a different car, the 2004 Ford Focus. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL SPECIFICATIONS

G04035160
 Slide Hammer
205-047 (15-011)
G04035161
 Mounting Bracket for 303-435 303-435-04 (21-064)
G04035162
 Locking Tool, Flywheel
303-254 (21-135)
G04035163
 Lifting Bracket, Engine
303-122 (21-068A)
G04035164
 Mounting Plate for 303-435-04 303-435-12 (21-150A)
G04035165
 Adapter for 205-047 303-633 (21-227)
G04035166
 Socket, Cylinder Head Bolt 303-392 (21-167)
GENERAL EQUIPMENT SPECIFICATIONS

Assembly stand
  1. Disconnect the oil pressure switch and the knock sensor (KS) electrical connectors.
    Fig 1: Disconnecting Oil Pressure Switch And Knock Sensor Electrical Connectors
    G04035167Courtesy of FORD MOTOR CO.
  2. Remove the generator.
    1. Disconnect the positive cable.
    2. Remove the bolt.
    3. Remove the bolt.
    Fig 2: Removing Generator
    G04035168Courtesy of FORD MOTOR CO.
  3. Remove the ancillary components on the intake side.
    1. Generator mounting bracket.
    2. Oil filter.
    3. Knock sensor (KS).
    4. Oil pressure switch.
    Fig 3: Removing Ancillary Components On Intake Side
    G04035169Courtesy of FORD MOTOR CO.
  4. Remove the oil cooler.
    Fig 4: Removing Oil Cooler
    G04035170Courtesy of FORD MOTOR CO.
  5. Install the mounting plate to the engine.
    Fig 5: Installing Mounting Plate To Engine
    G04035171Courtesy of FORD MOTOR CO.
  6. Install the mounting bracket to the mounting plate.
    Fig 6: Installing Mounting Bracket To Mounting Plate
    G04035172Courtesy of FORD MOTOR CO.
  7. Attach the engine to the assembly stand and remove the engine lifting bracket.
  8. Remove the ancillary components on the exhaust side.
    1. Power steering pump bracket.
    2. Air conditioning compressor bracket.
    Fig 7: Removing Ancillary Components On The Exhaust Side
    G04035173Courtesy of FORD MOTOR CO.
  9. Disconnect the positive crankcase ventilation.
    Fig 8: Disconnecting Positive Crankcase Ventilation
    G04035174Courtesy of FORD MOTOR CO.
  10. Remove the clutch assembly. For additional information, refer to CLUTCH - IB5 TRANSAXLE , CLUTCH - MTX75 TRANSAXLE or CLUTCH - MT285 TRANSAXLE .
  11. Using the special tool, lock the flywheel in position.
    Fig 9: Locking Flywheel In Position
    G04035175Courtesy of FORD MOTOR CO.
  12. Remove the timing belt cover.
    1. Water pump belt pulley.
    2. Drive belt idler pulley.
    3. Engine front mount bracket.
    4. Upper timing belt cover.
    5. Remove the damper from the crankshaft pulley.
    6. Lower timing belt cover.
    Fig 10: Removing Timing Belt Cover
    G04035176Courtesy of FORD MOTOR CO.
    13. CAUTION: Do not pull the spark plug electrical connectors by the ignition cables when removing them. If necessary disconnect the ignition cables from the ignition coils to prevent damage to the cables. Slightly twist the spark plug electrical connectors before removing them to loosen the seals.
    CAUTION: Pull off the spark plug electrical connectors in line with the spark plugs.
    Fig 11: Disconnecting Spark Plug Electrical Connectors
    G04035177Courtesy of FORD MOTOR CO.
  13. Disconnect the spark plug electrical connectors.
  14. Remove the valve cover.
    Fig 12: Removing Valve Cover
    G04035178Courtesy of FORD MOTOR CO.
    15. NOTE: Installation position of crankshaft timing belt pulley and thrust washer.
    Fig 13: Removing Crankshaft Timing Pulley And Thrust Washer
    G04035179Courtesy of FORD MOTOR CO.
  15. Remove the timing belt drive and the water pump.
    1. Slacken the timing belt tensioner by twisting it counter-clockwise and remove it.
    2. Remove the timing belt.
    3. Remove the idler pulley.
    4. Remove the water pump.
    5. Remove the crankshaft timing pulley and the thrust washer.
    16. NOTE: Hold the camshaft by the hexagon with an open ended wrench to prevent it from rotating.
    Fig 14: Removing Intake Camshaft Pulley Blanking Plug
    G04035180Courtesy of FORD MOTOR CO.
  16. Remove the intake camshaft pulley blanking plug.
    17. NOTE: Hold the camshafts by the hexagon with an open ended wrench to prevent them from rotating.
    Fig 15: Removing Camshaft Pulleys
    G04035181Courtesy of FORD MOTOR CO.
  17. Remove the camshaft pulleys.
  18. Remove the oil feed flange.
    • Discard the camshaft oil seals.
    • Discard the oil feed flange oil seal.
    Fig 16: Removing Oil Feed Flange
    G04035182Courtesy of FORD MOTOR CO.
    19. CAUTION: Loosen and remove the camshaft bearing cap retaining bolts in the sequence shown.
    NOTE: Working in several stages, evenly loosen each bolt two turns at a time in the sequence shown.
    Fig 17: Camshafts Removal Sequence
    G04035183Courtesy of FORD MOTOR CO.
  19. Remove the camshafts.
    • Remove the valve tappets and position them in order, to one side.
    20. CAUTION: The bolts can be re-used twice, center-punch the bolts.
    CAUTION: Remove the cylinder head bolts in the sequence shown.
    Fig 18: Cylinder Head Bolt Removal Sequence
    G04035184Courtesy of FORD MOTOR CO.
  20. Remove the cylinder head.
  21. Using the special tool, remove the flywheel.
    • Discard the bolts.
    Fig 19: Removing Flywheel
    G04035185Courtesy of FORD MOTOR CO.
  22. Remove the special tool.
  23. Remove the drain plug and the oil pan retaining bolts.
    • Allow the oil to drain into a suitable container.
    Fig 20: Removing Oil Pan Bolts
    G04035186Courtesy of FORD MOTOR CO.
    24. CAUTION: To prevent damage to the sealing surfaces, only use the special tool shown to remove the oil pan.
    NOTE: Tighten the locknut against the oil pan and tap the special tool several times to release the oil pan from the lower crankcase.
    Fig 21: Removing Oil Pan Using Special Tool
    G04035187Courtesy of FORD MOTOR CO.
  24. Using the special tool, remove the oil pan.
  25. Remove the oil intake pipe and the lower crankcase.
    1. Oil intake pipe bolts.
    2. Lower crankcase bolts.
    Fig 22: Removing Oil Intake Pipe And Lower Crankcase
    G04035188Courtesy of FORD MOTOR CO.
  26. Remove the oil pump.
    Fig 23: Removing Oil Pump
    G04035189Courtesy of FORD MOTOR CO.
  27. Remove the crankshaft rear oil seal carrier, crankshaft position (CKP) sensor and CKP bracket.
    Fig 24: Removing Crankshaft Rear Oil Seal Carrier, Crankshaft Position Sensor And CKP Bracket
    G04035190Courtesy of FORD MOTOR CO.
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