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Engine - 2.0L SPI: Disassembly: Engine

Fig 1: Identifying Special Tool(s) (1 Of 2)

G02206881

Courtesy of FORD MOTOR CO.

Fig 2: Identifying Special Tool(s) (2 Of 2)

G02206882

Courtesy of FORD MOTOR CO.

Disconnect the exhaust gas recirculation (EGR) tube from the EGR valve.

Fig 3: Disconnecting Exhaust Gas Recirculation (EGR) Tube From EGR Valve
Courtesy of FORD MOTOR CO.
Disconnect the EGR tube from the exhaust manifold.

Fig 4: Disconnecting EGR Tube From Exhaust Manifold
Courtesy of FORD MOTOR CO.
Remove the bolt and remove the oil level indicator tube.

Fig 5: Removing Bolt And Removing Oil Level Indicator Tube
Courtesy of FORD MOTOR CO.
Disconnect the crankshaft position (CKP) sensor electrical connector.

Fig 6: Disconnecting Crankshaft Position (CKP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the four fuel injector electrical connectors.

Fig 7: Disconnecting Four Fuel Injector Electrical Connectors
Courtesy of FORD MOTOR CO.
Disconnect the (A) idle air control (IAC) valve and the (B) throttle position (TP) sensor electrical connectors.

Fig 8: Disconnecting Idle Air Control (IAC) Valve And Throttle Position (TP) Sensor Electrical Connectors
Courtesy of FORD MOTOR CO.
Disconnect the following electrical connectors:
- Water temperature indicator sender unit.
- Ignition coil.
- Intake manifold runner control (IMRC).
- Knock sensor.
- Fuel pressure sensor.
Fig 9: Disconnecting Electrical Connectors
Courtesy of FORD MOTOR CO.
Disconnect the fuel pressure sensor electrical connector.

Fig 10: Disconnecting Fuel Pressure Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the fuel charging wire harness.
Remove the (A) bolts, the (B) stud, and the engine mounting bracket.

Fig 11: Removing Bolts Stud, And Engine Mounting Bracket
Courtesy of FORD MOTOR CO.
Remove the nuts, the intake manifold, the IMRC, and the gaskets.

Fig 12: Removing Nuts, Intake Manifold, IMRC, And Gaskets
Courtesy of FORD MOTOR CO.
Remove the spark plug wires.
Remove the oil filter.

Fig 13: Removing Oil Filter
Courtesy of FORD MOTOR CO.
Remove the oil pressure switch.

Fig 14: Removing Oil Pressure Switch
Courtesy of FORD MOTOR CO.
Remove the two bolts and the generator (GEN) (10346).

Fig 15: Removing Two Bolts And Generator
Courtesy of FORD MOTOR CO.

NOTE: Remove the nuts evenly and sequentially.

Fig 16: Removing Nuts, Exhaust Manifold And Gasket

G02206896

Courtesy of FORD MOTOR CO.

Remove the nuts, the exhaust manifold and the gasket.
Remove the four bolts and remove the ignition coil and radio ignition interference capacitor.

Fig 17: Removing Four Bolts And Removing Ignition Coil And Radio Ignition Interference Capacitor
Courtesy of FORD MOTOR CO.
Remove the bolts and the ignition coil mounting bracket assembly.

Fig 18: Removing Bolts And Ignition Coil Mounting Bracket Assembly
Courtesy of FORD MOTOR CO.
Remove the bolts, the water outlet connection, the thermostat, and the gasket.

Fig 19: Removing Bolts, Water Outlet Connection, Thermostat, And Gasket
Courtesy of FORD MOTOR CO.
Remove the four spark plugs.
Use Strap Wrench to remove the crankcase pulley bolt.

Fig 20: Removing Crankcase Pulley Bolt Using Special Tool
Courtesy of FORD MOTOR CO.
Remove the two bolts and the CKP sensor.

Fig 21: Removing Two Bolts And CKP Sensor
Courtesy of FORD MOTOR CO.
Remove the (A) three nuts, the (B) three bolts, and the outer engine front cover.

Fig 22: Removing Three Nuts, Three Bolts, And Outer Engine Front Cover
Courtesy of FORD MOTOR CO.
Align the timing marks.

Fig 23: Aligning Timing Marks
Courtesy of FORD MOTOR CO.
Remove the timing belt.
1. Use an 8 mm Allen wrench and turn counterclockwise 1/4 turn.
2. Insert a 1/8 drill bit to lock the timing belt tensioner in place.
3. Remove the timing belt.
Fig 24: Removing Timing Belt
Courtesy of FORD MOTOR CO.
Remove the (A) bolt and the (B) timing belt tensioner.

Fig 25: Removing Bolt And Timing Belt Tensioner
Courtesy of FORD MOTOR CO.
Use Camshaft Pulley Remover to remove the (A) camshaft sprocket bolt and washer and the (B) camshaft sprocket (6256).

Fig 26: Removing Camshaft Sprocket Bolt And Washer And Camshaft Sprocket
Courtesy of FORD MOTOR CO.
Remove the inner engine front cover.

Fig 27: Removing Inner Engine Front Cover
Courtesy of FORD MOTOR CO.
Remove the bolts and the stud and the water pump (8501) and gasket.

Fig 28: Removing Bolts And Stud And Water Pump And Gasket
Courtesy of FORD MOTOR CO.
Remove the crankshaft sprocket (6306) and the timing belt guide.

Fig 29: Removing Crankshaft Sprocket And Timing Belt Guide
Courtesy of FORD MOTOR CO.
Remove the three bolts and the power steering pump pulley (3A733).

Fig 30: Removing Three Bolts And Power Steering Pump Pulley
Courtesy of FORD MOTOR CO.
Remove the bolts and the power steering pump (3A674).

Fig 31: Removing Bolts And Power Steering Pump
Courtesy of FORD MOTOR CO.
Remove the five bolts and one nut and the front engine accessory drive bracket.

Fig 32: Removing Bolts And One Nut And Front Engine Accessory Drive Bracket
Courtesy of FORD MOTOR CO.
Remove the bolts and the valve cover (6582) and gasket.

Fig 33: Removing Bolts And Valve Cover And Gasket
Courtesy of FORD MOTOR CO.

NOTE: Remove the bolts evenly and sequentially.

Fig 34: Removing Cylinder Head Bolts

G02206914

Courtesy of FORD MOTOR CO.

Remove the ten cylinder head bolts, the cylinder head (6049), and the gasket. Discard the gasket.
Remove the bolts and remove the oil pan (6675) and oil pan gasket (6710). Discard the gasket.

Fig 35: Removing Oil Pan Bolts
Courtesy of FORD MOTOR CO.
Remove the bolts and the oil pump screen cover and tube (6622) and gasket. Discard the gasket.

Fig 36: Removing Bolts And Oil Pump Screen Cover And Tube And Gasket
Courtesy of FORD MOTOR CO.
Remove the nuts and the oil baffle.

Fig 37: Removing Nuts And Oil Baffle
Courtesy of FORD MOTOR CO.
Remove the six bolts and the oil pump (6600).
- Remove the crankshaft front seal from the oil pump.
Fig 38: Removing Oil Pump
Courtesy of FORD MOTOR CO.
Remove the bolts and the crankshaft rear seal retainer and gasket. Discard the gasket.

Fig 39: Removing Bolts And Crankshaft Rear Seal Retainer And Gasket
Courtesy of FORD MOTOR CO.
Remove the eight connecting rod cap nuts and the four connecting rod caps.

Fig 40: Removing Eight Connecting Rod Cap Nuts And Four Connecting Rod Caps
Courtesy of FORD MOTOR CO.
Install a short length of rubber tubing over the connecting rod bolts to avoid damage to the crankcase journals.

Fig 41: Installing Short Length Of Rubber Tubing Over Connecting Rod Bolts
Courtesy of FORD MOTOR CO.
Inspect the top of each cylinder bore before removing the piston (6108). 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 (6303) clockwise until the piston is at the bottom of its cylinder bore.
- Place a clean shop cloth over the piston head to collect cuttings.
- Use Cylinder Ridge Reamer and remove the ridge. Never cut into the ring travel area more than 0.8 mm (1/32 in) when removing the ridge.
Remove the pistons and the connecting rod assemblies.

Fig 42: Removing Pistons And Connecting Rod Assemblies
Courtesy of FORD MOTOR CO.
45.
NOTE: The crankshaft main bearings (6333) are precision selective fit. Refer to ENGINE SYSTEM-GENERAL INFORMATION to check the bearing clearances or to select fit a new crankshaft main bearing.

Remove the six crankshaft main bearing cap bolts and the four studs, the five main bearing caps, and the lower crankshaft main bearings.

Fig 43: Removing Six Crankshaft Main Bearing Cap Bolts And Four Studs
Courtesy of FORD MOTOR CO.
Remove the crankshaft.

Fig 44: Removing Crankshaft
Courtesy of FORD MOTOR CO.
Remove the (A) upper crankshaft main bearing and the (B) crankshaft thrust main bearing (6337).

Fig 45: Removing Upper Crankshaft Main Bearing And Crankshaft Thrust Main Bearing
Courtesy of FORD MOTOR CO.