Section 461 (Engine - 2.3L): Disassembly: Engine

Fig 1: Identifying Special Tool

Courtesy of FORD MOTOR CO.

VEHICLES WITH 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 2: Removing Clutch Pressure Plate & Clutch
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1. Remove the bolts, the clutch pressure plate and the clutch disc.

ALL VEHICLES 

2. Install the special tool and remove the flexplate.
   Fig 3: Installing Special Tool & Removing Flexplate

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3. Mount the engine on a suitable engine stand.
4. Remove the drive belt.
   Fig 4: Removing Drive Belt

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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 5: Removing Engine Oil Level Indicator Tube

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6. Remove the front coolant outlet pipe.
   1. Remove the bolts.
   2. Remove the water outlet tube.
      Fig 6: Removing Front Coolant Outlet Pipe

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7. Remove the A/C compressor.
   Fig 7: Removing A/C Compressor

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NOTE: The generator will be removed with the accessory bracket.
Fig 8: Removing Accessory Bracket
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8. Remove the accessory bracket.
9. Remove the right motor mount.
   Fig 9: Removing Right Motor Mount

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10. Disconnect the following:
    • The coolant hose from the thermostat.
    • The coolant hose from the PCV fitting on the intake manifold.
      Fig 10: Disconnecting Coolant Hose From Thermostat & PCV Fitting On Intake Manifold

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11. Remove the coolant tube assembly.
    Fig 11: Removing Coolant Tube Assembly

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12. Remove the exhaust manifold and gasket.
    Fig 12: Removing Exhaust Manifold And Gasket

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13. Remove the block heater, if so equipped.
    Fig 13: Removing Block Heater

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14. Remove the rear coolant outlet pipe.
    1. Disconnect the engine coolant temperature sender electrical connector.
    2. Remove the coolant hose.
    3. Remove the rear coolant outlet pipe and the mounting gasket.
       Fig 14: Removing Rear Coolant Outlet Pipe

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15. Remove the EGR valve.
    1. Disconnect the electrical connector.
    2. Disconnect the coolant hose.
    3. Remove the bolts and EGR valve.
       Fig 15: Removing EGR Valve

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16. Remove the power steering pump.
    Fig 16: Removing Power Steering Pump

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17. Disconnect the following electrical connectors:
    • Idle air control (IAC) valve
    • Throttle position (TP) sensor
    • Manifold absolute pressure (MAP) sensor
      Fig 17: Disconnecting Electrical Connectors

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18. Disconnect the crankshaft position (CKP) sensor and the wiring harness pin -type retainers.
    Fig 18: Disconnecting CKP Sensor & Wiring Harness

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19. Disconnect the knock sensor (KS) electrical connector and remove the engine wiring harness connector bracket. Position the engine wiring harness aside.
    Fig 19: Disconnecting KS Connector & Wiring Harness

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20. Disconnect the camshaft position (CMP) sensor electrical connector and disconnect the PCV hose from the intake manifold.
    Fig 20: Disconnecting CMP Sensor Connector & PCV Hose From Intake Manifold

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21. Disconnect the engine wiring harness pin-type retainers from the intake manifold.
22. Disconnect the EGR tube from the intake manifold.
    Fig 21: Disconnecting EGR Tube From Intake Manifold

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23. Remove the EGR tube.
    • Remove the EGR tube bracket from the intake manifold.
    • Disconnect the EGR tube from the cylinder head.
    • Remove the EGR tube.
      Fig 22: Removing EGR Tube

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24. Detach the fuel supply hose clip from the front of the intake manifold.
    Fig 23: Detaching Fuel Supply Hose Clip

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25. Remove the intake manifold assembly.
    Fig 24: Removing Intake Manifold Assembly

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26. Disconnect the fuel injector electrical connectors and the wiring harness pin -type retainers.
    Fig 25: Disconnecting Fuel Injector Connectors & Wiring Harness

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27. Disconnect the ignition coil and the cylinder head temperature (CHT) sensor electrical connectors.
    Fig 26: Disconnecting Ignition Coil & CHT Sensor

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28. Detach the engine wiring harness anchors from the valve cover studs. Remove the engine wiring harness.
    Fig 27: Detaching Engine Wiring Harness Anchors From Valve Cover

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CAUTION: Spark plug wires must be connected correctly. Mark the spark plug wires before removing them.
CAUTION: It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wires.
Fig 28: Removing Spark Plug Wires From Spark Plugs
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29. With a twisting motion, use the special tool to pull the spark plug wires off the spark plugs.
30. Remove the ignition coil.
    Fig 29: Removing Ignition Coil

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31. Remove the thermostat housing.
    Fig 30: Removing Thermostat Housing

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32. Remove the KS and the engine vent cover.
    Fig 31: Removing KS And Engine Vent Cover

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33. Remove the left motor mount.
    Fig 32: Removing Left Motor Mount

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34. Remove the fuel injector supply manifold with the injectors and the ground strap.
    Fig 33: Removing Fuel Injector Supply Manifold

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35. Remove the water pump pulley.
    Fig 34: Removing Water Pump Pulley

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36. Remove the water pump.
    Fig 35: Removing Water Pump

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37. Remove the following:
    • CMP sensor
    • CHT sensor
    • Spark plugs
      Fig 36: Removing CMP Sensor, CHT Sensor & Spark Plugs

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38. Remove the valve cover.
    Fig 37: Removing Valve Cover

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39. Remove the CKP sensor.
    Fig 38: Removing CKP Sensor

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CAUTION: The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, with diamond washers between the flange faces on each part. For that reason, if the pulley is loosened, the crankshaft sprocket is also unfastened. Therefore, the engine must be retimed each time the damper is removed. Otherwise severe engine damage can occur.
CAUTION: Failure to position the No. 1 piston at top dead center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only.
Fig 39: Turning Crankshaft to position No. 1 Piston At TDC
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40. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at TDC.
CAUTION: The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
NOTE: The camshaft timing slots are offset. If the special tool cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.
Fig 40: Installing Special Tool In Slots On Rear Of Camshafts
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41. Install the special tool in the slots on the rear of both camshafts.
42. Install the special tools.
    Fig 41: Installing Special Tool To Crankshaft Pulley

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CAUTION: Failure to hold the crankshaft pulley in place while loosening the bolts can cause damage to the engine.
43. Remove the crankshaft pulley.
    1. Remove the crankshaft pulley bolt.
    2. Remove the special tools.
    3. Remove the crankshaft pulley.
       Fig 42: Removing Crankshaft Pulley

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CAUTION: There is one front cover bolt behind the cooling fan drive pulley. To remove this bolt, align one of the cooling fan drive pulley access holes with the bolt head.
Fig 43: Removing Front Cover
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44. Remove the front cover.
45. 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 44: Removing Timing Chain Tensioner

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46. Remove the timing chain guides.
    Fig 45: Removing Timing Chain Guides

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47. Remove the timing chain assembly.
    Fig 46: Removing Timing Chain Assembly

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NOTE: Use a wrench on the flats between cylinders No. 1 and No. 2 to hold the camshaft in place.
Fig 47: Removing Camshaft Drive Sprockets
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48. Remove the camshaft drive sprockets.
49. 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 48: Removing Oil Pump Chain Tensioner And Guide

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NOTE: The oil pump chain sprocket must be held in place.
50. Remove the oil pump chain and sprockets.
    1. Remove the bolt.
    2. Remove the chain, sprockets and diamond washers.
       Fig 49: Removing Oil Pump Chain & Sprockets

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51. Remove the special tool.
    Fig 50: Removing Special Tool From Camshafts

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CAUTION: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.
NOTE: Note the position of the lobes on the No. 1 cylinder before removing the camshafts for assembly reference.
52. 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 51: Camshaft Bearing Caps Removal Sequence

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53. Remove the camshafts.
54. Remove the bolts and the cylinder head.
    Fig 52: Removing Bolts Of Cylinder Head

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55. Remove the cylinder head gasket.
56. Remove the cylinder head alignment dowels.
    Fig 53: Removing Cylinder Head Alignment Dowels

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57. Remove the bolts and the oil pan.
    Fig 54: Removing Bolts Of Oil Pan

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58. Remove the rear main oil seal.
    Fig 55: Removing Rear Main Oil Seal

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59. Remove the oil pump pickup tube and gasket.
    Fig 56: Removing Oil Pump Pickup Tube And Gasket

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60. Remove the oil pump assembly and gasket.
    Fig 57: Removing Oil Pump Assembly And Gasket

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