Disassembly

NOTE: Ford does not provide camshaft gear timing marks, or information to perform timing belt service without the special tools shown in this procedure.

Special Tools:

1. NOTE: The engine should stay hooked into the floor crane until it can be attached to the assembly stand.

When it is on the assemble stand the engine has to be temporarily unhooked from the Engine lifting bracket, secure it with securing straps.





2. Disconnect the Camshaft Position (CMP) sensor and the Engine Coolant Temperature (ECT) sensor electrical connectors.
- Detach the wiring from the Electronic Ignition (EI) coil.





3. Disconnect the oil pressure switch and Knock Sensor (KS) electrical connectors.





4. Remove the generator.
1 Disconnect the generator electrical connectors.
2 Remove the bolts.





5. Remove the intake manifold.
1 Disconnect the solenoid electrical connector.
2 Remove seven bolts and two nuts.





6. Remove the heat shield.
- Remove two bolts and one nut.
- Withdraw the engine oil level indicator tube.
- Attach the engine lifting eye again and hook it into the Engine lifting bracket.





7. Disconnect the Three Way Catalytic Converter (TWC) from the exhaust manifold.





8. Remove the bolt from the TWC bracket.





9. Remove the ancillary components on the intake side of the engine.
- Drain off the engine oil and install the drain plug.
1 Generator bracket.
2 Oil filter.
3 Knock Sensor (KS).
4 Oil pressure switch.
5 Remove the exhaust tube bracket and take out the exhaust tube.





10. Attach the engine to the assembly stand.
1 Install the mounting plate.
2 Install the mounting bracket.





11. Remove the ancillary components on the exhaust side of the engine.
1 TWC bracket.
2 Coolant hose from water pump and thermostat housing.
3 Power steering pump bracket.
4 Air Conditioning (A/C) compressor bracket.





12. Remove the crankcase ventilation.
1 Disconnect the crankcase ventilation tube.
2 Remove the three bolts.





13. Using the special tool, block the flywheel.





14. Remove the engine front cover.
1 Remove the water pump pulley.
2 Remove the idler pulley.
3 Remove the center part of the engine front cover.
4 Remove the upper part of the engine front cover.
5 Remove the crankshaft pulley/vibration damper.
6 Remove the lower part of the engine front cover.





15. Remove the valve cover.
1 Remove the appearance cover.
2 Disconnect the spark plug wires.
3 Remove the ten bolts.





16. Loosen the camshaft pulleys.
1 Remove the blanking plug from the exhaust camshaft timing belt pulley.

NOTE: Hold the camshaft by the hexagon with an open-ended wrench to stop it from turning.

2 Loosen the bolt one turn.

NOTE: Hold the intake camshaft pulley with the special tool 303-098 to stop it from turning.

3 Loosen the bolt one turn.





17. Remove the timing belt drive and the water pump.
1 Loosen the timing belt tensioner by turning the washer clockwise and remove it.
2 Remove the timing belt.
3 Remove the upper idler pulley.
4 Remove the lower idler pulley.
5 Remove the water pump.
6 Remove the crankshaft pulley and thrust washer.
- Remove the camshaft pulleys.





18. Remove the bolts from the Variable Camshaft Timing (VCT) oil feed flange.

19. NOTE: Loosening sequence: Working from the outside inwards, loosen the bolts evenly, undoing each one two turns at a time.





Remove the camshafts.
1 Remove the camshaft bearing caps.
2 Remove the intake camshaft.
3 Remove the exhaust camshaft together with the oil feed flange.
- Remove the spark plugs.

20. CAUTION: Wait until the cylinder head has cooled down to ambient temperature.

NOTE: Loosening sequence





Remove the bolts.
21. Remove the cylinder head.
- Using the Engine lifting bracket, hook it into the engine lifting eyes; lift off the cylinder head and place it on clean wooden blocks.





22. Using the special tool, remove the clutch pressure plate and the clutch disc (if equipped).





23. Using the special tool, remove the flywheel.

24. CAUTION: Remove the oil pan downwards. It is vital that no oil sludge or abraded particles enter the engine.





Remove the oil pan bolts.

25. CAUTION: Do not damage the mating faces. The drain plug must be tightened.





Remove the oil pan.
- Separate the oil pan from the lower crankcase using a sharp spatula. Release the oil pan from the lower crankcase by tapping slightly against the drain plug with a rubber hammer.





26. Remove the oil intake tube and the lower crankcase.
1 Remove the oil intake tube.
2 Remove the lower crankcase.





27. Remove the oil pump.





28. Remove the crankshaft rear oil seal carrier and the Crankshaft Position (CKP) sensor with its bracket.
1 Remove the CKP bolt.
2 Remove the four bolts.

29. NOTE: Place all parts in order to one side.





Remove the crankshaft and pistons.
1 Remove the connecting rod bearing caps.
2 Remove the main bearing caps.
3 Remove the crankshaft and press out the pistons with the connecting rods.