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Section 1325 (Engine - 2.0L SPI): Disassembly: Engine

WARNING: This page is about a different car, the 2004 Ford Focus. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL SPECIFICATIONS

G04034654
 Cylinder Ridge Reamer
303-016 (T64L-6011-EA)
G04034655
 Strap Wrench
303-D055 (D85L-6000-A)
  1. Disconnect and remove the following.
    • Vacuum hoses
    • Coolant hoses and tubes
    • Positive crankcase ventilation and fresh air hoses
  2. Remove the clutch (if equipped). For additional information, refer to CLUTCH - IB5 TRANSAXLE , CLUTCH - MTX75 TRANSAXLE or CLUTCH - MT285 TRANSAXLE .
  3. Remove the flywheel.
    • Install the special tool.
    • Remove the bolts.
    Fig 1: Removing Flywheel Bolts
    G04034656Courtesy of FORD MOTOR CO.
  4. Attach the engine to stand.
  5. Disconnect the exhaust gas recirculation tube from the EGR valve.
    Fig 2: Disconnecting Exhaust Gas Recirculation Tube From EGR Valve
    G04034657Courtesy of FORD MOTOR CO.
  6. Disconnect the EGR tube from the exhaust manifold.
    Fig 3: Disconnecting EGR Tube From Exhaust Manifold
    G04034658Courtesy of FORD MOTOR CO.
  7. Remove the oil lever indicator tube.
    Fig 4: Removing Oil Lever Indicator Tube
    G04034659Courtesy of FORD MOTOR CO.
  8. Disconnect the crankshaft position (CKP) sensor electrical connector.
    Fig 5: Disconnecting Crankshaft Position Sensor Electrical Connector
    G04034660Courtesy of FORD MOTOR CO.
  9. Disconnect the fuel injectors electrical connectors.
    Fig 6: Disconnecting Fuel Injectors Electrical Connectors
    G04034661Courtesy of FORD MOTOR CO.
  10. Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor electrical connectors.
    Fig 7: Disconnecting Idle Air Control Valve And Throttle Position Sensor Electrical Connectors
    G04034662Courtesy of FORD MOTOR CO.
  11. Disconnect the oil pressure sender unit and the knock sensor.
    Fig 8: Disconnecting Oil Pressure Sender Unit And Knock Sensor
    G04034663Courtesy of FORD MOTOR CO.
  12. Disconnect the fuel pressure sensor electrical connector.
    Fig 9: Disconnecting Fuel Pressure Sensor Electrical Connector
    G04034664Courtesy of FORD MOTOR CO.
  13. Disconnect the electrical connectors.
    • Camshaft position (CMP) sensor
    • Intake manifold runner control (IMRC)
    • Radio interference capacitor
    • Ignition coil
    • Water temperature indicator sender unit
    Fig 10: Disconnecting Electrical Connectors
    G04034665Courtesy of FORD MOTOR CO.
  14. Detach the retainers and remove the fuel charge wiring harness.
    Fig 11: Removing Fuel Charge Wiring Harness
    G04034666Courtesy of FORD MOTOR CO.
  15. Remove the intake manifold bracket.
    Fig 12: Removing Intake Manifold Bracket
    G04034667Courtesy of FORD MOTOR CO.
    16. CAUTION: Use care not to drop any components.
    Fig 13: Removing Intake Manifold And IMRC
    G04034668Courtesy of FORD MOTOR CO.
  16. Remove the intake manifold and IMRC.
    • Discard the gaskets.
    17. CAUTION: Do not pull on the ignition wires directly, as wires may separate from the connector inside the boot.
    Fig 14: Disconnecting Spark Plug Wires
    G04034669Courtesy of FORD MOTOR CO.
  17. Disconnect the spark plug wires.
  18. Remove the ignition coil, ignition coil bracket and wires as one assembly.
    Fig 15: Removing Ignition Coil, Ignition Coil Bracket And Wires Assembly
    G04034670Courtesy of FORD MOTOR CO.
  19. Remove the oil filter.
    Fig 16: Removing Oil Filter
    G04034671Courtesy of FORD MOTOR CO.
  20. Remove the knock sensor.
    Fig 17: Removing Knock Sensor
    G04034672Courtesy of FORD MOTOR CO.
  21. Remove the oil pressure sender unit.
    Fig 18: Removing Oil Pressure Sender Unit
    G04034673Courtesy of FORD MOTOR CO.
  22. Remove the CKP sensor.
    Fig 19: Removing CKP Sensor
    G04034674Courtesy of FORD MOTOR CO.
  23. Remove the generator.
    Fig 20: Removing Generator
    G04034675Courtesy of FORD MOTOR CO.
  24. Remove the accessory drive belt bracket.
    Fig 21: Removing Accessory Drive Belt Bracket
    G04034676Courtesy of FORD MOTOR CO.
    25. NOTE: Remove the nuts evenly.
    Fig 22: Removing Exhaust Manifold
    G04034677Courtesy of FORD MOTOR CO.
  25. Remove the exhaust manifold.
    • Discard the gasket.
  26. Remove the water outlet connection, thermostat and gasket.
    Fig 23: Removing Water Outlet Connection, Thermostat And Gasket
    G04034678Courtesy of FORD MOTOR CO.
    27. NOTE: If an original spark plug is reused, install it in the same cylinder from which it was removed. New spark plugs may be installed in any cylinder.
    Fig 24: Removing Spark Plugs
    G04034679Courtesy of FORD MOTOR CO.
  27. Remove the spark plugs.
    28. NOTE: Using the special tool, hold the crankshaft pulley.
    Fig 25: Removing Crankshaft Pulley
    G04034680Courtesy of FORD MOTOR CO.
  28. Remove the crankshaft pulley.
  29. Remove the timing belt cover.
    Fig 26: Removing Timing Belt Cover
    G04034681Courtesy of FORD MOTOR CO.
  30. Remove the upper timing belt cover.
    Fig 27: Removing Upper Timing Belt Cover
    G04034682Courtesy of FORD MOTOR CO.
  31. Align the timing marks.
    Fig 28: Aligning Timing Marks
    G04034683Courtesy of FORD MOTOR CO.
  32. Remove the timing belt.
    1. Use an 8 mm Allen key and turn counterclockwise one-fourth turn.
    2. Insert a 3 mm (1/8 inch) drill bit to lock the timing belt tensioner in place.
    3. Remove the timing belt.
    Fig 29: Removing Timing Belt
    G04034684Courtesy of FORD MOTOR CO.
  33. Remove the timing belt tensioner.
    1. Remove the bolt.
    2. Remove the tensioner.
    Fig 30: Removing Timing Belt Tensioner
    G04034685Courtesy of FORD MOTOR CO.
  34. Remove the water pump.
    • Discard the gasket.
    Fig 31: Removing Water Pump
    G04034686Courtesy of FORD MOTOR CO.
  35. Remove the crankshaft sprocket and the timing belt guide.
    Fig 32: Removing Crankshaft Sprocket And Timing Belt Guide
    G04034687Courtesy of FORD MOTOR CO.
  36. Remove the valve cover.
    Fig 33: Removing Valve Cover
    G04034688Courtesy of FORD MOTOR CO.
    37. NOTE: Remove the bolts evenly and sequentially.
    Fig 34: Removing Cylinder Head
    G04034689Courtesy of FORD MOTOR CO.
  37. Remove the cylinder head.
    • Discard the gasket.
    38. NOTE: Mark location of the two stud bolts.
    Fig 35: Removing Oil Pan
    G04034690Courtesy of FORD MOTOR CO.
  38. Remove the oil pan.
    • Discard the gasket.
  39. Remove the oil pump screen cover and tube.
    • Discard the gasket.
    Fig 36: Removing Oil Pump Screen Cover And Tube
    G04034691Courtesy of FORD MOTOR CO.
  40. Remove the oil baffle.
    Fig 37: Removing Oil Baffle
    G04034692Courtesy of FORD MOTOR CO.
  41. Remove the oil pump.
    • Discard the gasket.
    Fig 38: Removing Oil Pump
    G04034693Courtesy of FORD MOTOR CO.
  42. Remove and discard the oil pump seal.
    Fig 39: Removing Oil Pump Seal
    G04034694Courtesy of FORD MOTOR CO.
  43. Remove the crankshaft rear seal retainer.
    • Discard the gasket.
    Fig 40: Removing Crankshaft Rear Seal Retainer
    G04034695Courtesy of FORD MOTOR CO.
  44. Remove the four connection rod caps.
    Fig 41: Removing Connection Rod Caps
    G04034696Courtesy of FORD MOTOR CO.
  45. Install a short length of rubber tubing over the connection rod bolts to avoid damage to the crankcase journals.
    Fig 42: Installing Short Length Of Rubber Tubing Over Connection Rod Bolts
    G04034697Courtesy of FORD MOTOR CO.
  46. Inspect the top of each cylinder bore before removing the piston. If a ridge has formed at the top of the cylinder, the ridge must be removed before the pistons can be removed. Remove the ridge as follows:
    • Turn the crankshaft clockwise until the piston is at the bottom of its cylinder bore.
    • Place a clean ship cloth over the piston head to collect cuttings.
    • Using the special tool 303-016 (T64L-6011-EA), remove the ridge. Never cut into the ring travel area more than 0.8 mm (1/32 in) when removing the ridge.
  47. Remove the pistons and the connecting rod assemblies.
    Fig 43: Removing Pistons And Connecting Rod Assemblies
    G04034698Courtesy of FORD MOTOR CO.
    48. NOTE: The crankshaft main bearings are precision selective fit. Check bearing clearances or select fit a new crankshaft main bearing. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
    Fig 44: Removing Main Bearing Caps And Lower Crankshaft Main Bearings
    G04034699Courtesy of FORD MOTOR CO.
  48. Remove the five main bearing caps and the lower crankshaft main bearings.
  49. Remove the crankshaft.
    Fig 45: Removing Crankshaft
    G04034700Courtesy of FORD MOTOR CO.
  50. Remove the bearings.
    1. Upper crankshaft main bearings.
    2. Crankshaft thrust main bearing.
    Fig 46: Removing Bearings
    G04034701Courtesy of FORD MOTOR CO.
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