Section 2 (Engine-2.0L ZETEC): Disassembly: Engine: Disassembly

All Vehicles 

1. General remarks.
   • The engine remains hooked onto the workshop hoist until the assembly stand can be attached.
   • If the engine is positioned on the assembly stand and needs to be temporarily unhooked from the workshop hoist, then it must be secured with retaining straps.
   • Cut cable ties as necessary and install new during installation.
2. Detach the catalytic converter bracket.
   Fig 1: Detaching Catalytic Converter Bracket

   Courtesy of FORD MOTOR CO.
3. Detach the catalytic converter.
   1. Detach the heat shield.
   2. Remove the EGR pipe.
   3. Unscrew the bolt from the catalytic converter bracket.
   Fig 2: Detaching Catalytic Converter (1 Of 2)

   Courtesy of FORD MOTOR CO.
4. Detach the catalytic converter (cont).
   Fig 3: Detaching Catalytic Converter (2 Of 2)

   Courtesy of FORD MOTOR CO.
5. Disconnect the multiplug from the oil pressure switch and the knock sensor (KS).
   Fig 4: Disconnecting Multiplug

   Courtesy of FORD MOTOR CO.
6. Detach the generator.
   1. Disconnect the positive cable.
   2. Unscrew the bolt.
   3. Loosen the bolt.
   Fig 5: Detaching Generator

   Courtesy of FORD MOTOR CO.
7. Detach the intake manifold.
   • Remove the five bolts and unscrew two nuts.
   Fig 6: Detaching Intake Manifold

   Courtesy of FORD MOTOR CO.
8. Detach the ancillary components on the intake side.
   1. Generator mounting bracket
   2. Oil filter
   3. Knock sensor (KS)
   4. Oil pressure switch
   Fig 7: Detaching Ancillary Components On Intake Side

   Courtesy of FORD MOTOR CO.
9. Attach the engine to the assembly stand.
10. Detach the ancillary components on the exhaust side.
    1. Bracket for power steering pump
    2. Bracket for air conditioning compressor
    Fig 8: Detaching Ancillary Components On Exhaust Side

    Courtesy of FORD MOTOR CO.
11. Disconnect the positive crankcase ventilation.
    Fig 9: Disconnecting Positive Crankcase Ventilation

    Courtesy of FORD MOTOR CO.
12. Detach the timing belt cover.
    1. Water pump belt pulley.
    2. Drive belt idler pulley.
    3. Center timing belt cover/front engine mounting bracket.
    4. Upper timing belt cover.
    NOTE: Immobilize the flywheel using Special Tool 303-103.
    5. Detach the pulley/vibration damper from the crankshaft.
    6. Lower timing belt cover.
    Fig 10: Detaching Timing Belt Cover

    Courtesy of FORD MOTOR CO.
CAUTION: Do not pull the spark plug connectors by the wire when removing them. If necessary pull off the ignition cables from the ignition coils to prevent kinking the cables. Slightly twist the spark plug connectors before removing them in order to loosen the seals.
CAUTION: Pull off the spark plug connectors in line with the spark plugs.
Fig 11: Detaching Cylinder Head Cover
Courtesy of FORD MOTOR CO.
13. Detach the cylinder head cover.
    • Pull off the spark plug connectors.
    1. Remove the bolts.
    2. Remove the spark plugs.
14. Detach the timing belt drive and the water pump.
    1. Slacken the timing belt tensioner by twisting it counterclockwise and detach it.
    2. Remove the timing belt.
    3. Detach the upper idler pulley.
    4. Detach the water pump.
    5. Detach the crankshaft timing pulley and the thrust washer.
    Fig 12: Detaching Timing Belt Drive And Water Pump

    Courtesy of FORD MOTOR CO.
15. Detach the camshaft timing pulleys.
    • Use the special tool to stop them turning.
    Fig 13: Detaching Camshaft Timing Pulleys

    Courtesy of FORD MOTOR CO.
NOTE: Working in several stages, evenly loosen each bolt two turns at a time in the indicated sequence and remove the bolts.
Fig 14: Camshaft Bearing Caps Bolts Removing Sequence
Courtesy of FORD MOTOR CO.
16. Detach the camshaft bearing caps.
    • Remove the oil seals.
    • Take out the camshafts.
    • Remove the valve tappets and lay them in order to one side.
CAUTION: Center-punch the bolts once or twice to mark them for re-use. The bolts can be re-used twice. Discard the bolts as necessary.
CAUTION: The cylinder head must cool down to room temperature before proceeding.
NOTE: Loosening sequence.
Fig 15: Cylinder Head Bolts Removal Sequence
Courtesy of FORD MOTOR CO.
17. Remove the cylinder head bolts.
18. Lift off the cylinder head.
    • Hook the workshop hoist onto the engine lifting eyes, lift off the cylinder head and place it down onto clean blocks of wood.

Vehicles With Manual Transmission 

19. Detach the clutch pressure plate and the clutch disc.
    Fig 16: Detaching Clutch Pressure Plate And Clutch Disc (W/ Manual Transmission)

    Courtesy of FORD MOTOR CO.

All Vehicles 

20. Detach the flywheel.
    • Detach the special tool.
      Fig 17: Detaching Flywheel

      Courtesy of FORD MOTOR CO.
21. Remove the oil pan bolts.
    Fig 18: Removing Oil Pan Bolts

    Courtesy of FORD MOTOR CO.
CAUTION: Do not damage the mating faces.
22. Remove the oil pan (shown with engine removed).
    • Separate the oil pan from the lower crankcase using a sharp spatula. Release the oil pan from the lower crankcase by tapping slightly against the tightened drain plug with a rubber hammer.
      Fig 19: Removing Oil Pan

      Courtesy of FORD MOTOR CO.
23. Detach the oil intake pipe and the lower crankcase.
    1. Oil intake pipe bolts
    2. Lower crankcase bolts
       Fig 20: Detaching Oil Intake Pipe And Lower Crankcase

       Courtesy of FORD MOTOR CO.
24. Detach the oil pump.
    Fig 21: Detaching Oil Pump

    Courtesy of FORD MOTOR CO.
25. Detach the crankshaft rear oil seal carrier and the crankshaft position (CKP) sensor together with its bracket.
    Fig 22: Detaching Crankshaft Rear Oil Seal Carrier And Crankshaft Position Sensor

    Courtesy of FORD MOTOR CO.
NOTE: Lay all parts in order to one side.
26. Remove the crankshaft and pistons.
    1. Detach the connecting rod bearing caps.
    2. Detach the main bearing caps.
    3. Take out the crankshaft and press out the pistons with the connecting rods.
       Fig 23: Removing Crankshaft And Pistons

       Courtesy of FORD MOTOR CO.