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Section 310 (Engine-2.3L): 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.

    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 Clutch Pressure Plate & Clutch Disc
    G01611564Courtesy of FORD MOTOR CO.
  1. Remove the bolts, the clutch pressure plate and the clutch disc.

    2. All vehicles 

  2. Remove the flywheel or flexplate.
    Fig 2: Removing Flywheel Or Flexplate Bolts
    G01611565Courtesy 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
    G01611566Courtesy 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
      G01611567Courtesy 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 Bolts
      G01611568Courtesy of FORD MOTOR CO.
  7. Remove the generator.
    Fig 6: Removing Generator
    G01611569Courtesy 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
    G01611570Courtesy of FORD MOTOR CO.
  9. Disconnect the heater hose from the thermostat housing.
    Fig 8: Disconnecting Heater Hose From Thermostat Housing
    G01611571Courtesy of FORD MOTOR CO.
  10. Disconnect the knock sensor (KS) electrical connector.
    Fig 9: Disconnecting Knock Sensor Electrical Connector
    G01611572Courtesy of FORD MOTOR CO.
  11. Remove the block heater, if equipped.
    Fig 10: Removing Block Heater
    G01611573Courtesy 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
      G01611574Courtesy of FORD MOTOR CO.
  13. Disconnect the throttle position (TP) sensor electrical connector.
    Fig 12: Disconnecting Throttle Position (TP) Sensor Electrical Connector
    G01611575Courtesy of FORD MOTOR CO.
  14. Disconnect the idle air control (IAC) motor electrical connector.
    Fig 13: Disconnecting Idle Air Control (IAC) Motor Electrical Connector
    G01611576Courtesy of FORD MOTOR CO.
  15. Disconnect the swirl control valve monitor electrical connector.
    Fig 14: Disconnecting Swirl Control Valve Monitor Electrical Connector
    G01611577Courtesy of FORD MOTOR CO.
  16. Disconnect the crankshaft position (CKP) sensor and the wiring harness pin-type retainers.
    Fig 15: Disconnecting Crankshaft Position (CKP) Sensor And Wiring Harness Pin-Type Retainers
    G01611578Courtesy of FORD MOTOR CO.
  17. Disconnect the camshaft position (CMP) sensor electrical connector.
    Fig 16: Disconnecting Camshaft Position (CMP) Sensor Electrical Connector
    G01611579Courtesy of FORD MOTOR CO.
  18. Remove the positive crankcase ventilation (PCV) hose.
    Fig 17: Removing Positive Crankcase Ventilation (PCV) Hose
    G01611580Courtesy 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
    G01611581Courtesy of FORD MOTOR CO.
  20. Remove the intake manifold assembly.
    Fig 19: Removing Intake Manifold Assembly
    G01611582Courtesy 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
    G01611583Courtesy of FORD MOTOR CO.
  22. Position aside the cylinder head temperature (CHT) boot.
    Fig 21: Positioning Aside Cylinder Head Temperature (CHT) Boot
    G01611584Courtesy of FORD MOTOR CO.
  23. Disconnect the CHT sensor electrical connector.
    Fig 22: Disconnecting CHT Sensor Electrical Connector
    G01611585Courtesy of FORD MOTOR CO.
  24. Remove the bypass hose.
    Fig 23: Removing Bypass Hose
    G01611586Courtesy of FORD MOTOR CO.
  25. Remove the thermostat housing.
    Fig 24: Removing Thermostat Housing
    G01611587Courtesy of FORD MOTOR CO.
  26. Remove the knock sensor and the engine vent cover.
    Fig 25: Removing Knock Sensor And Engine Vent Cover
    G01611588Courtesy of FORD MOTOR CO.
  27. Remove the fuel injection supply manifold with the injectors.
    Fig 26: Removing Fuel Injection Supply Manifold With Injectors
    G01611589Courtesy of FORD MOTOR CO.
  28. Remove the coolant pump pulley.
    Fig 27: Removing Coolant Pump Pulley
    G01611590Courtesy of FORD MOTOR CO.
  29. Remove the coolant pump.
    Fig 28: Removing Coolant Pump
    G01611591Courtesy 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 And Spark Plugs
      G01611592Courtesy of FORD MOTOR CO.
  32. Remove the valve cover.
    Fig 30: Removing Valve Cover
    G01611593Courtesy of FORD MOTOR CO.
  33. Remove the CKP sensor.
    Fig 31: Removing CKP Sensor
    G01611594Courtesy of FORD MOTOR CO.
  34. Remove the crankshaft vibration damper bolt and the vibration damper.
    Fig 32: Removing Crankshaft Vibration Damper Bolt
    G01611595Courtesy of FORD MOTOR CO.
  35. Remove the engine front cover.
    Fig 33: Removing Engine Front Cover
    G01611596Courtesy 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
      G01611597Courtesy of FORD MOTOR CO.
  37. Remove the timing chain guides.
    Fig 35: Removing Timing Chain Guides
    G01611598Courtesy of FORD MOTOR CO.
  38. Remove the timing chain assembly.
    Fig 36: Removing Timing Chain Assembly
    G01611599Courtesy 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
    G01611600Courtesy 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
      G01611601Courtesy of FORD MOTOR CO.
    41. NOTE: The oil pump chain sprocket must be held in place.
  41. Remove the oil pump chain and sprockets.
    1. Remove the bolt.
    2. Remove the chain and sprockets.
      Fig 39: Removing Oil Pump Chain And Sprockets
      G01611602Courtesy of FORD MOTOR CO.
    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.
  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.
      Fig 40: Identifying Camshaft Bearing Caps Bolts Loosening Sequence
      G01611603Courtesy of FORD MOTOR CO.
  43. Remove the camshafts.
  44. Remove the bolts and the cylinder head.
    Fig 41: Removing Cylinder Head Bolts
    G01611604Courtesy of FORD MOTOR CO.
  45. Remove the cylinder head gasket.
  46. Remove the cylinder head alignment dowels.
    Fig 42: Removing Cylinder Head Alignment Dowels
    G01611605Courtesy of FORD MOTOR CO.
  47. Remove the bolts and the oil pan.
    Fig 43: Removing Oil Pan Bolts
    G01611606Courtesy of FORD MOTOR CO.
  48. Remove the crankshaft rear main oil seal.
    Fig 44: Removing Crankshaft Rear Main Oil Seal
    G01611607Courtesy of FORD MOTOR CO.
  49. Remove the oil pump pickup tube and gasket.
    Fig 45: Removing Oil Pump Pickup Tube And Gasket
    G01611608Courtesy of FORD MOTOR CO.
  50. Remove the oil pump assembly and gasket.
    Fig 46: Removing Oil Pump Assembly And Gasket
    G01611609Courtesy of FORD MOTOR CO.
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