LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Ford >> 2000 >> ZX2 Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1327 (Engine - 2.3L) >> Disassembly >> Engine
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Section 1327 (Engine - 2.3L): 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

G04035669
 Engine Stand
014-00232 or equivalent
G04035670
 Locking Tool, Flywheel
303-103 (T74P-8375-A)
CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure.
CAUTION: The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley. Therefore, the engine must be retimed each time the damper is removed. Otherwise severe damage can occur.
CAUTION: Due to the precision fit and timing of the balancer shaft assembly, it cannot be removed from the engine block.
NOTE: For additional information, refer to DESCRIPTION AND OPERATION .

Vehicles equipped with a manual transmission 

    CAUTION: If the clutch disc and pressure plate are to be reinstalled, bolts must be removed evenly or permanent damage to the diaphragm spring will occur, resulting in complete clutch release.
    NOTE: If the parts are to be reused, index-mark the clutch pressure plate to the flywheel.
    Fig 1: Removing Bolts, Clutch Pressure Plate And Clutch Disc
    G04035671Courtesy of FORD MOTOR CO.
  1. Remove the bolts, the clutch pressure plate and the clutch disc.

    2. All vehicles 

  2. Install the special tool and remove the flywheel or flexplate.
    Fig 2: Removing Flywheel Or Flexplate
    G04035672Courtesy of FORD MOTOR CO.
  3. Mount the engine on a suitable engine stand.
  4. Remove the accessory drive belt.
    Fig 3: Removing Accessory Drive Belt
    G04035673Courtesy of FORD MOTOR CO.
  5. Remove the engine oil level indicator assembly.
    1. Remove the engine oil level indicator.
    2. Remove the bolts.
    3. Remove the engine oil level indicator tube.
    Fig 4: Removing Engine Oil Level Indicator Assembly
    G04035674Courtesy of FORD MOTOR CO.
  6. Remove the coolant bypass.
    1. Remove the hose.
    2. Remove the bolts and the coolant bypass.
    Fig 5: Removing Coolant Bypass
    G04035675Courtesy of FORD MOTOR CO.
  7. Remove the generator.
    Fig 6: Removing Generator
    G04035676Courtesy of FORD MOTOR CO.
  8. Disconnect the coolant tube from the exhaust gas recirculation (EGR) valve.
    Fig 7: Disconnecting Coolant Tube From Exhaust Gas Recirculation Valve
    G04035677Courtesy of FORD MOTOR CO.
  9. Disconnect the heater hose from the thermostat housing.
    Fig 8: Disconnecting Heater Hose From Thermostat Housing
    G04035678Courtesy of FORD MOTOR CO.
  10. Disconnect the knock sensor (KS) electrical connector.
    Fig 9: Disconnecting Knock Sensor Electrical Connector
    G04035679Courtesy of FORD MOTOR CO.
  11. Remove the block heater, if equipped.
    Fig 10: Removing Block Heater
    G04035680Courtesy of FORD MOTOR CO.
  12. Remove the EGR valve.
    1. Disconnect the electrical connector.
    2. Remove the bolts.
    3. Remove the EGR valve.
    Fig 11: Removing EGR Valve
    G04035681Courtesy of FORD MOTOR CO.
  13. Disconnect the throttle position (TP) sensor electrical connector.
    Fig 12: Disconnecting Throttle Position Sensor Electrical Connector
    G04035682Courtesy of FORD MOTOR CO.
  14. Disconnect the idle air control (IAC) motor electrical connector.
    Fig 13: Disconnecting Idle Air Control Motor Electrical Connector
    G04035683Courtesy of FORD MOTOR CO.
  15. Disconnect the swirl control valve monitor electrical connector.
    Fig 14: Disconnecting Swirl Control Valve Monitor Electrical Connector
    G04035684Courtesy of FORD MOTOR CO.
  16. Disconnect the crankshaft position (CKP) sensor and the wiring harness pin-type retainers.
    Fig 15: Disconnecting Crankshaft Position Sensor And Wiring Harness Pin-Type Retainers
    G04035685Courtesy of FORD MOTOR CO.
  17. Disconnect the camshaft position (CMP) sensor electrical connector.
    Fig 16: Disconnecting Camshaft Position Sensor Electrical Connector
    G04035686Courtesy of FORD MOTOR CO.
  18. Remove the positive crankcase ventilation (PCV) hose.
    Fig 17: Removing Positive Crankcase Ventilation Hose
    G04035687Courtesy of FORD MOTOR CO.
  19. Disconnect the engine wiring harness pin-type retainers from the intake manifold.
    Fig 18: Disconnecting Engine Wiring Harness Pin-Type Retainers From Intake Manifold
    G04035688Courtesy of FORD MOTOR CO.
  20. Remove the intake manifold assembly.
    Fig 19: Removing Intake Manifold Assembly
    G04035689Courtesy of FORD MOTOR CO.
  21. Disconnect the fuel injector electrical connectors and the wiring harness pin-type retainers.
    Fig 20: Disconnecting Fuel Injector Electrical Connectors And Wiring Harness Pin-Type Retainers
    G04035690Courtesy of FORD MOTOR CO.
  22. Position aside the cylinder head temperature (CHT) boot.
    Fig 21: Positioning Aside Cylinder Head Temperature Boot
    G04035691Courtesy of FORD MOTOR CO.
  23. Disconnect the CHT sensor electrical connector.
    Fig 22: Disconnecting CHT Sensor Electrical Connector
    G04035692Courtesy of FORD MOTOR CO.
  24. Remove the bypass hose.
    Fig 23: Removing Bypass Hose
    G04035693Courtesy of FORD MOTOR CO.
  25. Remove the thermostat housing.
    Fig 24: Removing Thermostat Housing
    G04035694Courtesy of FORD MOTOR CO.
  26. Remove the knock sensor and the engine vent cover.
    Fig 25: Removing Knock Sensor And Engine Vent Cover
    G04035695Courtesy of FORD MOTOR CO.
  27. Remove the fuel injection supply manifold with the injectors.
    Fig 26: Removing Fuel Injection Supply Manifold With Injectors
    G04035696Courtesy of FORD MOTOR CO.
  28. Remove the coolant pump pulley.
    Fig 27: Locating Coolant Pump Pulley Bolts
    G03897969Courtesy of FORD MOTOR CO.
  29. Remove the coolant pump.
    Fig 28: Locating Coolant Pump Bolts
    G03897970Courtesy of FORD MOTOR CO.
  30. Remove the bolts and the ignition coils.
  31. Remove the following:
    • CMP sensor.
    • CHT sensor.
    • Spark plugs.
    Fig 29: Removing CMP Sensor, CHT Sensor & Spark Plugs
    G04035699Courtesy of FORD MOTOR CO.
  32. Remove the valve cover.
    Fig 30: Removing Valve Cover
    G04035700Courtesy of FORD MOTOR CO.
  33. Remove the CKP sensor.
    Fig 31: Removing CKP Sensor
    G04035701Courtesy of FORD MOTOR CO.
  34. Remove the crankshaft vibration damper bolt and the vibration damper.
    Fig 32: Removing Crankshaft Vibration Damper Bolt And Vibration Damper
    G04035702Courtesy of FORD MOTOR CO.
  35. Remove the engine front cover.
    Fig 33: Removing Engine Front Cover
    G04035703Courtesy of FORD MOTOR CO.
  36. Remove the timing chain tensioner.
    1. Compress the timing chain tensioner plunger and insert a paper clip into the location shown.
    2. Remove the bolts.
    Fig 34: Removing Timing Chain Tensioner Bolts
    G04035704Courtesy of FORD MOTOR CO.
  37. Remove the timing chain guides.
    Fig 35: Removing Timing Chain Guides
    G04035705Courtesy of FORD MOTOR CO.
  38. Remove the timing chain assembly.
    Fig 36: Removing Timing Chain Assembly
    G04035706Courtesy of FORD MOTOR CO.
    39. NOTE: Use a wrench on the flats between cylinders No. 1 and No. 2 to hold the camshaft in place.
    Fig 37: Removing Camshaft Drive Sprockets
    G04035707Courtesy of FORD MOTOR CO.
  39. Remove the camshaft drive sprockets.
  40. Remove the oil pump chain tensioner and guide.
    1. Release the tension on the tensioner spring.
    2. Remove the tensioner and the shoulder bolt.
    3. Remove the guide.
    Fig 38: Removing Oil Pump Chain Tensioner And Guide
    G04035708Courtesy of FORD MOTOR CO.
    41. NOTE: The oil pump chain sprocket must be held in place.
    Fig 39: Removing Oil Pump Chain And Sprockets
    G04035709Courtesy of FORD MOTOR CO.
  41. Remove the oil pump chain and sprockets.
    1. Remove the bolt.
    2. Remove the chain and sprockets.
    42. CAUTION: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.
    NOTE: Mark the position of the lobes on the No. 1 cylinder before removing the camshafts for assembly reference.
    Fig 40: Removing Camshaft Bearing Caps
    G04035710Courtesy of FORD MOTOR CO.
  42. Remove the camshaft bearing caps.
    1. Loosen the camshaft bearing cap bolts in sequence, one turn at a time.
    2. Repeat the first step until all tension is released from the camshaft bearing caps.
    3. Remove the camshaft bearing caps.
  43. Remove the camshafts.
  44. Remove the bolts and the cylinder head.
    Fig 41: Removing Bolts And Cylinder Head
    G04035711Courtesy of FORD MOTOR CO.
  45. Remove the cylinder head gasket.
  46. Remove the cylinder head alignment dowels.
    Fig 42: Identifying Cylinder Head Alignment Dowels
    G03898024Courtesy of FORD MOTOR CO.
  47. Remove the bolts and the oil pan.
    Fig 43: Removing Bolts And Oil Pan
    G04035713Courtesy of FORD MOTOR CO.
  48. Remove the crankshaft rear main oil seal.
    Fig 44: Removing Crankshaft Rear Main Oil Seal
    G04035714Courtesy of FORD MOTOR CO.
  49. Remove the oil pump pickup tube and gasket.
    Fig 45: Removing Oil Pump Pickup Tube And Gasket
    G04035715Courtesy of FORD MOTOR CO.
  50. Remove the oil pump assembly and gasket.
    Fig 46: Removing Oil Pump Assembly And Gasket
    G04035716Courtesy of FORD MOTOR CO.
scientia non olet · About LEMON Manuals