Section 308 (Engine-2.0L SPI): Disassembly: Engine: Disassembly

WARNING: This page is about a different car, the 2003 Ford Focus. However, it is still accessible from the selected car via links, so may be relevant.

Disconnect and remove the following.
- Vacuum hoses
- Coolant hoses and tubes
- Positive crankcase ventilation and fresh air hoses
Remove the clutch (if equipped). For additional information, refer to CLUTCH-IB5 TRANSAXLE , CLUTCH-MTX75 TRANSAXLE or CLUTCH-MT285 TRANSAXLE .
Remove the flywheel.
- Install the special tool.
- Remove the bolts.
  
  Fig 1: Removing Flywheel
  Courtesy of FORD MOTOR CO.
Attach the engine to stand.
Disconnect the exhaust gas recirculation tube from the EGR valve.

Fig 2: Disconnecting Exhaust Gas Recirculation Tube
Courtesy of FORD MOTOR CO.
Disconnect the EGR tube from the exhaust manifold.

Fig 3: Disconnecting EGR Tube From Exhaust Manifold
Courtesy of FORD MOTOR CO.
Remove the oil lever indicator tube.

Fig 4: Removing Oil Lever Indicator Tube
Courtesy of FORD MOTOR CO.
Disconnect the crankshaft position (CKP) sensor electrical connector.

Fig 5: Disconnecting Crankshaft Position Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the fuel injectors electrical connectors.

Fig 6: Disconnecting Fuel Injectors Electrical Connectors
Courtesy of FORD MOTOR CO.
Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor electrical connectors.

Fig 7: Disconnecting Idle Air Control Valve And Throttle Position Sensor Electrical Connectors
Courtesy of FORD MOTOR CO.
Disconnect the oil pressure sender unit and the knock sensor.

Fig 8: Disconnecting Oil Pressure Sender Unit And Knock Sensor
Courtesy of FORD MOTOR CO.
Disconnect the fuel pressure sensor electrical connector.

Fig 9: Disconnecting Fuel Pressure Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the electrical connectors.
- Camshaft position (CMP) sensor
- Intake manifold runner control (IMRC)
- Radio interference capacitor
- Ignition coil
- Water temperature indicator sender unit
  
  Fig 10: Disconnecting Electrical Connectors
  Courtesy of FORD MOTOR CO.
Detach the retainers and remove the fuel charge wiring harness.

Fig 11: Removing Fuel Charge Wiring Harness
Courtesy of FORD MOTOR CO.
Remove the intake manifold bracket.

Fig 12: Removing Intake Manifold Bracket
Courtesy of FORD MOTOR CO.

CAUTION: Use care not to drop any components.

Remove the intake manifold and IMRC.
- Discard the gaskets.
  
  Fig 13: Removing Intake Manifold And IMRC
  Courtesy of FORD MOTOR CO.

CAUTION: Do not pull on the ignition wires directly, as wires may separate from the connector inside the boot.

Fig 14: Disconnecting Spark Plug Wires

Courtesy of FORD MOTOR CO.

Disconnect the spark plug wires.
Remove the ignition coil, ignition coil bracket and wires as one assembly.

Fig 15: Removing Ignition Coil, Ignition Coil Bracket And Wires
Courtesy of FORD MOTOR CO.
Remove the oil filter.

Fig 16: Removing Oil Filter
Courtesy of FORD MOTOR CO.
Remove the knock sensor.

Fig 17: Removing Knock Sensor
Courtesy of FORD MOTOR CO.
Remove the oil pressure sender unit.

Fig 18: Removing Oil Pressure Sender Unit
Courtesy of FORD MOTOR CO.
Remove the CKP sensor.

Fig 19: Removing CKP Sensor
Courtesy of FORD MOTOR CO.
Remove the generator.

Fig 20: Removing Generator
Courtesy of FORD MOTOR CO.
Remove the accessory drive belt bracket.

Fig 21: Removing Accessory Drive Belt Bracket
Courtesy of FORD MOTOR CO.

NOTE: Remove the nuts evenly. Remove the exhaust manifold.

- Discard the gasket.
  
  Fig 22: Removing Exhaust Manifold
  Courtesy of FORD MOTOR CO.
Remove the water outlet connection, thermostat and gasket.

Fig 23: Removing Water Outlet Connection, Thermostat And Gasket
Courtesy of FORD MOTOR CO.

NOTE: If an original spark plug is reused, install it in the same cylinder from which it was removed. New spark plugs may be installed in any cylinder.

Fig 24: Removing Spark Plugs

Courtesy of FORD MOTOR CO.

Remove the spark plugs.

NOTE: Using the special tool, hold the crankshaft pulley.

Fig 25: Removing Crankshaft Pulley

Courtesy of FORD MOTOR CO.

Remove the crankshaft pulley.
Remove the timing belt cover.

Fig 26: Removing Timing Belt Cover
Courtesy of FORD MOTOR CO.
Remove the upper timing belt cover.

Fig 27: Removing Upper Timing Belt Cover
Courtesy of FORD MOTOR CO.
Align the timing marks.

Fig 28: Aligning Timing Marks
Courtesy of FORD MOTOR CO.
Remove the timing belt.
1. Use an 8 mm Allen key and turn counterclockwise one-fourth turn.
2. Insert a 3 mm (1/8 inch) drill bit to lock the timing belt tensioner in place.
3. Remove the timing belt.
  
  Fig 29: Removing Timing Belt
  Courtesy of FORD MOTOR CO.
Remove the timing belt tensioner.
1. Remove the bolt.
2. Remove the tensioner.
  
  Fig 30: Removing Timing Belt Tensioner
  Courtesy of FORD MOTOR CO.
Remove the water pump.
- Discard the gasket.
  
  Fig 31: Removing Water Pump
  Courtesy of FORD MOTOR CO.
Remove the crankshaft sprocket and the timing belt guide.

Fig 32: Removing Crankshaft Sprocket And Timing Belt Guide
Courtesy of FORD MOTOR CO.
Remove the valve cover.

Fig 33: Removing Valve Cover
Courtesy of FORD MOTOR CO.

NOTE: Remove the bolts evenly and sequentially.

Remove the cylinder head.
- Discard the gasket.
  
  Fig 34: Removing Cylinder Head
  Courtesy of FORD MOTOR CO.

NOTE: Mark location of the two stud bolts.

Remove the oil pan.
- Discard the gasket.
  
  Fig 35: Removing Oil Pan
  Courtesy of FORD MOTOR CO.
Remove the oil pump screen cover and tube.
- Discard the gasket.
  
  Fig 36: Removing Oil Pump Screen Cover And Tube
  Courtesy of FORD MOTOR CO.
Remove the oil baffle.

Fig 37: Removing Oil Baffle
Courtesy of FORD MOTOR CO.
Remove the oil pump.
- Discard the gasket.
  
  Fig 38: Removing Oil Pump
  Courtesy of FORD MOTOR CO.
Remove and discard the oil pump seal.

Fig 39: Removing Oil Pump Seal
Courtesy of FORD MOTOR CO.
Remove the crankshaft rear seal retainer.
- Discard the gasket.
  
  Fig 40: Removing Crankshaft Rear Seal Retainer
  Courtesy of FORD MOTOR CO.
Remove the four connection rod caps.

Fig 41: Removing Four Connection Rod Caps
Courtesy of FORD MOTOR CO.
Install a short length of rubber tubing over the connection rod bolts to avoid damage to the crankcase journals.

Fig 42: Installing Short Length Of Rubber Tubing
Courtesy of FORD MOTOR CO.
Inspect the top of each cylinder bore before removing the piston. If a ridge has formed at the top of the cylinder, the ridge must be removed before the pistons can be removed. Remove the ridge as follows:
- Turn the crankshaft clockwise until the piston is at the bottom of its cylinder bore.
- Place a clean ship cloth over the piston head to collect cuttings.
- Using the special tool 303-016 (T64L-6011-EA), remove the ridge. Never cut into the ring travel area more than 0.8 mm (1/32 in) when removing the ridge.
Remove the pistons and the connection rod assemblies.

Fig 43: Removing Pistons And Connection Rod Assemblies
Courtesy of FORD MOTOR CO.

NOTE: The crankshaft main bearings are precision selective fit. Check bearing clearances or select fit a new crankshaft main bearing. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .

Fig 44: Removing Main Bearing Caps

Courtesy of FORD MOTOR CO.

Remove the five main bearing caps and the lower crankshaft main bearings.
Remove the crankshaft.

Fig 45: Removing Crankshaft
Courtesy of FORD MOTOR CO.
Remove the bearings.
1. Upper crankshaft main bearings.
2. Crankshaft thrust main bearing.
  
  Fig 46: Removing Upper Crankshaft And Thrust Main Bearings
  Courtesy of FORD MOTOR CO.