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.





1. Disconnect the camshaft position (CMP) sensor and the engine coolant temperature (ECT) sensor electrical connectors.
- Disconnect the wiring from the electronic ignition (EI) coil.




2. Disconnect the oil pressure switch and knock sensor (KS) electrical connectors.





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






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






5. Remove the heat shield.
- Remove two bolts and one nut and remove the heat shield.
- Remove the engine oil level indicator and tube.






6. Disconnect the catalytic converter from the exhaust manifold.
- Remove the nuts.






7. Remove the bolt from the catalytic converter bracket.





8. Remove the components on the intake side of the engine.
1 Remove the bolts and the generator bracket.
2 Remove the oil filter and oil filter adapter.
3 Remove the knock sensor (KS).
4 Remove the oil pressure switch.
5 Remove the exhaust tube bracket and remove the exhaust tube.





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






10. Remove the components on the exhaust side of the engine.
1 Remove the bolts and the catalytic converter bracket.
2 Remove the coolant hose from coolant pump and thermostat housing.
3 Remove the bolts and the power steering pump bracket.
4 Remove the bolts and the air conditioning compressor bracket.






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

NOTE: Immobilize the flywheel using Flywheel Holding Tool.






12. Remove the timing belt cover.
1 Remove the bolts and the coolant pump pulley.
2 Remove the bolt and the drive belt idler pulley.
3 Remove the bolts and the center timing belt cover.
4 Remove the upper timing belt cover.
5 Remove the crankshaft pulley bolt and the crankshaft pulley.
6 Remove the bolts and the lower timing belt cover.






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

NOTE: Use a Cam Sprocket Holding/Removing Tool to stop the timing pulley from turning.






14. Loosen the camshaft timing pulleys.
1 Remove the blanking plug.
2 Loosen the exhaust bolt one turn.
3 Loosen the intake bolt one turn.






15. Remove the timing belt and the coolant pump.
1 Loosen the timing belt tensioner by rotating it clockwise.
2 Remove the timing belt and remove the timing belt pulleys.
3 Remove the bolt and the upper idler pulley.
4 Remove the bolt and the lower idler pulley.
5 Remove the bolts and the coolant pump.
6 Remove the crankshaft timing pulley and thrust washer.






16. Remove the bolts from the oil feed flange.

CAUTION: Wait until the cylinder head has cooled to room temperature before removing the camshafts from the cylinder head.

NOTE: The camshaft caps must be removed in the indicated sequence.






17. Remove the camshafts.
- Remove the camshaft cap bolts in the indicated sequence in several passes and remove the camshafts.

CAUTION: Do not remove cylinder head until engine has completely cooled to room temperature.

NOTE: The cylinder head bolts are torqued to yield and must not be reused.






18. Remove the cylinder head bolts in the indicated sequence and remove the cylinder head.
- Discard the bolts.






19. On manual transaxle equipped vehicles, remove the clutch pressure plate and the clutch disk.





20. On automatic transaxle equipped vehicles, remove the flywheel.





21. Remove the oil pan bolts.





22. Remove the oil pan.





23. Remove the lower crankcase.
1 Remove the bolts and the oil intake tube.
2 Remove the ten bolts and remove the lower crankcase.






24. Remove the oil pump.





25. Remove the crankshaft rear oil seal carrier and the crankshaft position (CKP) sensor with its bracket.
1 Remove the bolt and remove the CKP.
2 Remove the four bolts and remove the rear oil seal carrier.






26. 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.