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Engine-2.0L ZETEC: Disassembly: Engine

Fig 1: Identifying Special Tools
G02738937Courtesy of FORD MOTOR CO.
CAUTION: The engine sealing surfaces are soft metals. Do not use abrasive grinding discs to remove gasket material, use only manual scrapers. Do not scratch or gouge the aluminum sealing surfaces.
  1. Using the special tool, lock the flywheel to the engine.
    Fig 2: Locking Flywheel To Engine
    G02738938Courtesy of FORD MOTOR CO.
    2. WARNING: The clutch disc and clutch pressure plate are heavy and may fall if not held when the bolts are removed. Failure to follow these instructions may result in personal injury.
    CAUTION: Loosen the bolts evenly to prevent pressure plate damage.
    Fig 3: Removing Clutch Pressure Plate And Clutch Disc
    G02738939Courtesy of FORD MOTOR CO.
  2. Remove the bolts, clutch pressure plate and clutch disc.
  3. Remove the flywheel.
    Fig 4: Removing Flywheel
    G02738940Courtesy of FORD MOTOR CO.
  4. Remove the special tool.
    Fig 5: Removing Special Tool
    G02738941Courtesy of FORD MOTOR CO.
  5. Remove rear cover plates and dowels.
    Fig 6: Removing Rear Cover Plates And Dowels
    G02738942Courtesy of FORD MOTOR CO.
  6. Using the special tool, remove the crankshaft rear seal.
    Fig 7: Removing Crankshaft Rear Seal
    G02738943Courtesy of FORD MOTOR CO.
  7. Inspect the crankshaft rear oil seal area.
    Fig 8: Identifying Crankshaft Rear Oil Seal Area For Inspection
    G02738944Courtesy of FORD MOTOR CO.
    8. NOTE: Install a new pilot bearing only if it is damaged.
    Fig 9: Removing Pilot Bearing
    G02738945Courtesy of FORD MOTOR CO.
  8. Use the special tool to remove the pilot bearing.
    1. Install the special tool.
    2. Remove the pilot bearing.
  9. Mount the engine on a suitable engine stand.
  10. Remove the bolt and the oil level indicator and tube.
    Fig 10: Removing Oil Level Indicator And Tube
    G02738946Courtesy of FORD MOTOR CO.
  11. Remove the six bolts and three nuts and remove the exhaust manifold.
    • Discard the gasket.
    Fig 11: Removing Exhaust Manifold Bolts & Nuts
    G02738947Courtesy of FORD MOTOR CO.
  12. Remove the power steering pump bracket.
    Fig 12: Removing Power Steering Pump Bracket
    G02738948Courtesy of FORD MOTOR CO.
  13. Remove the A/C compressor bracket.
    Fig 13: Removing A/C Compressor Bracket
    G02738949Courtesy of FORD MOTOR CO.
  14. Remove the coolant tube.
    • Remove the bolt and nut.
    • Disconnect the hose.
    Fig 14: Removing Coolant Tube
    G02738950Courtesy of FORD MOTOR CO.
  15. Remove the crankshaft position (CKP) sensor.
    Fig 15: Removing Crankshaft Position (CKP) Sensor
    G02738951Courtesy of FORD MOTOR CO.
  16. Remove the crankcase vent oil separator.
    1. Disconnect the positive crankcase ventilation (PCV) valve.
    2. Remove the bolts and remove the separator.
      • Discard the gasket.
    Fig 16: Removing Crankcase Vent Oil Separator
    G02738952Courtesy of FORD MOTOR CO.
  17. Remove the coolant tube.
    • Remove the bolt.
    • Disconnect the hose.
    Fig 17: Removing Coolant Tube
    G02738953Courtesy of FORD MOTOR CO.
  18. Remove the bolt and remove the crankshaft pulley.
    Fig 18: Removing Crankshaft Pulley
    G02738954Courtesy of FORD MOTOR CO.
  19. Remove the accessory drive belt idler pulley.
    Fig 19: Removing Accessory Drive Belt Idler Pulley
    G02738955Courtesy of FORD MOTOR CO.
  20. Remove the lower timing belt cover.
    Fig 20: Removing Lower Timing Belt Cover
    G02738956Courtesy of FORD MOTOR CO.
  21. Remove the water pump pulley.
    Fig 21: Removing Water Pump Pulley
    G02738957Courtesy of FORD MOTOR CO.
  22. Remove the lower engine mount bracket.
    Fig 22: Removing Lower Engine Mount Bracket
    G02738958Courtesy of FORD MOTOR CO.
  23. Disconnect the wire harness.
    Fig 23: Disconnecting Wire Harness
    G02738959Courtesy of FORD MOTOR CO.
  24. Remove the upper timing belt cover.
    Fig 24: Removing Upper Timing Belt Cover
    G02738960Courtesy of FORD MOTOR CO.
  25. Remove the timing belt tensioner and remove and discard the timing belt.
    Fig 25: Removing Timing Belt Tensioner
    G02738961Courtesy of FORD MOTOR CO.
  26. Remove the water pump adapter.
    Fig 26: Removing Water Pump Adapter
    G02738962Courtesy of FORD MOTOR CO.
  27. Remove the timing belt idler pulley.
    Fig 27: Removing Timing Belt Idler Pulley
    G02738963Courtesy of FORD MOTOR CO.
  28. Remove the ignition wires from the spark plugs.
    Fig 28: Removing Ignition Wires From Spark Plugs
    G02738964Courtesy of FORD MOTOR CO.
  29. Disconnect the wire harness and position aside.
    Fig 29: Disconnecting Wire Harness
    G02738965Courtesy of FORD MOTOR CO.
  30. Remove the valve cover.
    • Remove the studbolts.
    • Remove the bolts.
    Fig 30: Removing Valve Cover Studbolts & Bolts
    G02738966Courtesy of FORD MOTOR CO.
    31. CAUTION: The camshaft alignment tool is not recommended to hold the camshafts in place when removing or tightening the bolts. Damage to camshaft may result.
    NOTE: Use an open-end wrench to keep each camshaft from rotating.
    Fig 31: Removing Camshaft Timing Sprockets
    G02738967Courtesy of FORD MOTOR CO.
  31. Remove the bolts and the camshaft timing sprockets.
    32. CAUTION: Cylinder head camshaft journal caps are numbered on the outside flats to make sure that they are assembled in their original positions. Failure to do so may result in engine damage.
    Fig 32: Identifying Removal Sequence Of Camshaft Journal Cap Bolts
    G02738968Courtesy of FORD MOTOR CO.
  32. Remove the camshafts.
    • Loosen the camshaft journal cap bolts in several two-turn passes in the sequence shown.
    • Remove the bolts.
    • Remove the caps.
    33. CAUTION: If the camshaft and valve tappets are to be reused, mark the location of the valve tappets to make sure that they are assembled in their original positions.
    Fig 33: Removing Valve Tappets From Cylinder Head
    G02738969Courtesy of FORD MOTOR CO.
  33. Remove the valve tappets from the cylinder head.
  34. Remove the inner timing belt cover.
    Fig 34: Removing Inner Timing Belt Cover
    G02738970Courtesy of FORD MOTOR CO.
  35. Remove the generator.
    Fig 35: Removing Generator
    G02738971Courtesy of FORD MOTOR CO.
  36. Remove the generator bracket.
    Fig 36: Removing Generator Bracket
    G02738972Courtesy of FORD MOTOR CO.
  37. Disconnect the following electrical connectors and remove the fuel charging wiring harness from the engine:
    1. cylinder temperature sensor
    2. throttle position sensor
    3. wiring harness to vehicle
    4. idle air control valve
    5. camshaft position sensor
    6. fuel injectors
    Fig 37: Disconnecting Electrical Connectors And Fuel Charging Wiring Harness From Engine
    G02738973Courtesy of FORD MOTOR CO.
  38. Disconnect EGR tube fitting.
    Fig 38: Disconnecting EGR Tube Fitting
    G02738974Courtesy of FORD MOTOR CO.
  39. Remove the EGR tube.
    Fig 39: Removing EGR Tube
    G02738975Courtesy of FORD MOTOR CO.
    40. NOTE: The coil is removed from the picture for clarity.
    Fig 40: Removing Coil And Bracket Assembly
    G02738976Courtesy of FORD MOTOR CO.
  40. Remove the coil and bracket assembly.
  41. Remove the thermostat housing.
    • Inspect and install a new O-ring seal if damaged.
    Fig 41: Removing Thermostat Housing
    G02738977Courtesy of FORD MOTOR CO.
  42. Remove the PCV tube.
    Fig 42: Removing PCV Tube
    G02738978Courtesy of FORD MOTOR CO.
    43. NOTE: Illustration shown with throttle body and fuel supply manifold removed for clarity.
    Fig 43: Identifying Removal Sequence Of Intake Manifold Nuts And Bolts
    G02738979Courtesy of FORD MOTOR CO.
  43. Remove the intake manifold.
    • Remove the two nuts and five bolts in the sequence shown.
  44. Remove the oil pressure sensor.
    Fig 44: Removing Oil Pressure Sensor
    G02738980Courtesy of FORD MOTOR CO.
  45. Remove the block heater if equipped.
    Fig 45: Removing Block Heater
    G02738981Courtesy of FORD MOTOR CO.
  46. Remove the knock sensor.
    Fig 46: Removing Knock Sensor
    G02738982Courtesy of FORD MOTOR CO.
  47. Remove the oil cooler.
    Fig 47: Removing Oil Cooler
    G02738983Courtesy of FORD MOTOR CO.
  48. Remove the crankshaft sprocket and timing belt guide.
    Fig 48: Removing Crankshaft Sprocket And Timing Belt Guide
    G02738984Courtesy of FORD MOTOR CO.
    49. CAUTION: The bolts are torque-to-yield, new bolts must be installed or engine damage can occur.
    Fig 49: Identifying Removal Sequence Of Cylinder Head Bolts
    G02738985Courtesy of FORD MOTOR CO.
  49. Remove the cylinder head using the sequence shown.
    • Discard the gasket.
    • Discard the bolts.
  50. Remove the 17 bolts and the oil pan.
    Fig 50: Removing Oil Pan
    G02738986Courtesy of FORD MOTOR CO.
  51. Remove the bolts and the oil pump cover and screen.
    • Carefully remove and discard the oil pump inlet tube gasket.
    Fig 51: Removing Oil Pump Cover And Screen
    G02738987Courtesy of FORD MOTOR CO.
  52. Remove the lower cylinder block and the gasket.
    Fig 52: Removing Lower Cylinder Block
    G02738988Courtesy of FORD MOTOR CO.
  53. Remove the seven bolts and the oil pump.
    • Remove the oil pump to cylinder block gasket.
    Fig 53: Removing Oil Pump Bolts
    G02738989Courtesy of FORD MOTOR CO.
  54. Remove the rear main oil seal retainer assembly and discard the gasket.
    Fig 54: Removing Rear Main Oil Seal Retainer Assembly
    G02738990Courtesy of FORD MOTOR CO.
    55. CAUTION: The connecting rods and connecting rod caps must be correctly oriented and, the interlocking tangs on the same side of the connecting rod or possible engine damage may occur.
    CAUTION: The connecting rod bolts are torque-to-yield. Discard the connecting rod bolts.
    Fig 55: Removing Connecting Rod Caps
    G02738991Courtesy of FORD MOTOR CO.
  55. Remove the four connecting rod caps.
  56. If the connecting rod bearings are to be reused, each one must be identified so that it can be installed in its original location. Remove the four upper and four lower connecting rod bearings.
    Fig 56: Removing Upper And Lower Connecting Rod Bearings
    G02738992Courtesy of FORD MOTOR CO.
  57. Use a suitable tool and remove the cylinder ridge.
    Fig 57: Removing Cylinder Ridge
    G02738993Courtesy of FORD MOTOR CO.
  58. Remove the four piston and connecting rod assemblies.
    Fig 58: Removing Piston And Connecting Rod Assemblies
    G02738994Courtesy of FORD MOTOR CO.
    59. CAUTION: Make sure the main bearing caps are installed in their original position or possible engine damage may occur.
    Fig 59: Removing Crankshaft Main Bearing Caps And Bearings
    G02738995Courtesy of FORD MOTOR CO.
  59. Remove the bolts and remove the crankshaft main bearing caps and bearings.
  60. Remove the crankshaft.
    Fig 60: Removing Crankshaft
    G02738996Courtesy of FORD MOTOR CO.
  61. Remove the upper crankshaft main bearings.
    Fig 61: Removing Upper Crankshaft Main Bearings
    G02738997Courtesy of FORD MOTOR CO.
  62. Remove the Woodruff key.
    Fig 62: Removing Woodruff Key
    G02738998Courtesy of FORD MOTOR CO.
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