Removal

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:

Removal

CAUTION: The maximum amount by which the engine management system will adjust the camshaft timing (VCT control unit) is limited to two degrees. As a result of this an extremely high degree of accuracy is required for any work which affects the valve timing.

NOTE: The locations of engine mountings and engine support insulators are described looking from the transaxle to the engine.

NOTE: Operation steps which only apply to certain model variants and therefore do not apply to all vehicles are clearly marked.

1. Disconnect the battery ground cable.

2. WARNING: When releasing the system pressure, cover the coolant expansion tank cup with a thick cloth to prevent the possibility of scalding. Failure to follow these instruction will result in personal injury.

Release the coolant expansion tank cap.
3. Loosen the RH front wheel nuts.
4. Raise and support the vehicle.
- Remove the right-hand front wheel.





5. Remove the engine undershield (if equipped).
- Remove the front right-hand wheel.





6. WARNING: When the engine is hot there is a risk of scalding.

Remove the radiator splash shield and drain the coolant.
1 Remove the six bolts.
2 Unscrew the radiator drain plug.





7. Remove the right-hand splash shields.





8. Remove the accessory drive belt.
1 Loosen the water pump pulley bolts.
2 Working clockwise, loosen the accessory drive belt and take it off.
- Remove the water pump pulley.
3 Remove the idler pulley.





9. Remove the crankshaft pulley/ vibration damper.





10. Remove the lower part of the engine front cover.





11. NOTE: It should be possible to insert the special tools free of strain in the subframe and body locating bores. Realign later as necessary.

Using the special tools, check the position of the subframe.

Vehicles with manual transaxle





12. Loosen the bolts of the right-hand engine support insulator two turns.
1 On the transaxle mounting bracket.
2 On the subframe.

Vehicles with automatic transaxle





13. Loosen the bolt of the right-hand engine support insulator two turns.

All Vehicles





14. NOTE: The engine support insulator cannot be removed at this stage.

Remove the left-hand engine support insulator.





15. Using the special tool, align the subframe (as necessary).
- Unscrew the subframe bolts two turns.

NOTE: The subframe must not move during the tightening operation.

1 With the special tools installed, tighten the four bolts, working diagonally.
2 Remove the special tools.





16. Remove the power steering pump lower bolts.





17. Disconnect the brake booster line and the crankcase ventilation hose from the intake manifold.





18. Disconnect the oil pressure switch and the Knock Sensor (KS) electrical connector
19. Lower the vehicle.





20. Remove the intake pipe.
1 Disconnect the Mass Air Flow (MAF) sensor electrical connector.
2 Disconnect the Intake Air Temperature (IAT) sensor electrical connector.
3 Remove the bolt and the two nuts.





21. Remove the Air Cleaner (ACL).
1 Disconnect the crankcase ventilation hose.
2 Disconnect the intake hose.





22. Disconnect the speed control cable.
1 Disconnect the cable from throttle valve.
2 Move the cable up and down and pull it out of the retaining bushing.
3 Press the retaining bushing out of the bracket.





23. Disconnect the throttle cable.
1 Remove the plastic clip and position the throttle cable to one side.
2 Unhook the cable.





24. Disconnect the wiring harness rail and the vacuum hoses.
- Disconnect the cylinder head wiring harness electrical connector.
- Disconnect the vacuum hoses.
- Unscrew the upper wiring harness rail bolts on the intake manifold.





25. Disconnect the starter motor positive lead.
- Remove the undershield.

CAUTION: Do not bend the fusible element when undoing the nut as there is a risk of it breaking.

- Unscrew the nut.





26. Disconnect the electrical connectors.
1 Radio interference suppressor.
2 Ignition coil.
3 Engine Coolant Temperature (ECT) sensor.
4 Power Steering Pressure (PSP) switch.
- Position the wiring to one side.





27. Remove the thermostat housing.
1 Disconnect the Camshaft Position (CMP) sensor electrical connector.
2 Disconnect the coolant hoses and position to one side.
3 Unscrew the bolts.





28. Detach the Positive Crankcase Ventilation (PCV) line.





29. Remove the exhaust manifold heat shield.
1 Unscrew the upper bolts.
- Remove the coolant hose bracket and the engine lifting eye, and pull out the engine oil level indicator tube.
2 Remove the coolant hose bracket clamp.
3 Remove the lower bolts.





30. Disconnect the Three-Way Catalytic Converter (TWC) from the exhaust manifold.
- Disconnect the Heated Oxygen Sensor (HO2S) electrical connector.





31. Remove the pulley cover.





32. Detach the coolant expansion tank and position it to one side.
- Disconnect the speed control cable (if equipped) from the coolant expansion tank.





33. Detach the power steering pump.
1 Remove the power steering pump bracket from the cylinder head.
2 Remove the upper power steering pump bolts.





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





35. Remove the generator bracket.
36. Raise and support the vehicle.

Vehicles with manual transaxle





37. Remove the left-hand engine support insulator.
- Remove the left-hand engine support insulator bracket.
- Remove the left-hand engine support insulator.
- Install the bracket again.

Vehicles with automatic transaxle
38. Remove the left-hand engine support insulator.
- Slightly lift the engine with a Transmission jack and remove the left-hand engine support insulator.

All Vehicles





39. Install the special tool in the place of the left-hand engine support insulator.
40. Lower the vehicle.

41. CAUTION: Place a block of wood under the oil pan to prevent denting.

Support the engine with a jack.





42. Remove the front support insulators.





43. Remove the upper part of the engine front belt cover.

NOTE: Use a Torx E 10 bit.

1 Remove the studs.
2 Remove the bolts.





44. Disconnect the solenoid valve connector and remove the appearance cover,
1 Disconnect the solenoid valve electrical connector.
2 Remove the bolts.





45. NOTE: Loosening sequence: From the outside inwards, working diagonally.

Remove the valve cover.
1 Disconnect the HT wires from the spark plugs.
2 Disconnect the crankcase ventilation hose.
3 Remove the ten bolts.





46. Remove the center part of the engine front cover/front engine mounting bracket.





47. Loosen the timing belt.
1 Loosen the bolt and release the timing belt tensioner by turning it clockwise.
2 Unscrew the bolt four turns and unhook the timing belt tensioner.





48. Remove the camshaft pulleys.
- Remove the timing belt.
1 Remove the blanking plug from the exhaust camshaft pulley.

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

2 Remove the exhaust camshaft pulley.
3 Remove the intake camshaft pulley.





49. Remove the bolts from the Variable Camshaft Timing (VCT) oil feed flange and the upper part of the engine front cover.





50. NOTE: Working evenly in several stages, unscrew each bolt two turns at a time.

Loosening sequence of the camshaft bearing caps.





51. NOTE: Loosening sequence

Remove the camshafts.
1 Remove the camshaft bearing caps.
2 Remove the intake camshaft.
3 Remove the exhaust camshaft with the VCT control unit.
- Remove the valve tappets.





52. WARNING: Wait until the cylinder head has cooled down to ambient temperature. Failure to follow this instruction may result in personal injury.

NOTE: Loosening sequence

Remove the cylinder head bolts.
53. Remove the cylinder head.
- Using the Workshop hoist hook it into the engine lifting eyes; lift off the cylinder head and place it on clean Wooden blocks.
- Discard the cylinder head gasket.