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Disassembly and Assembly of Subassemblies > < Engine - Vehicles With: Manual Transaxle

Maverick 2001 (12.2000-07.2004)

Engine - 2.0L Zetec-E (Zetec) - Engine Maverick 2001 (12/2000-07/2004)
Disassembly

Special Tool(s)

Puller With Slide Hammer

308-001 (T58L-101-B)

Heavy Duty Floor Crane

014-00072 or equivalent

Engine Stand

014-00232 or equivalent

Flywheel Holding Tool

303-103 (T74P-6375-A)

Spreader Bar

303-D089 (D93P-6001-A3)

Seal Remover

303-409 (T92C-6700-CH)
CAUTION:
CAUTION:The engine sealing surfaces are soft metals. Do not use abrasive grinding discs to remove gasket material, use only manual scrapers. Do not scratch or gouge the aluminum sealing surfaces.
  1. Using the special tool, lock the flywheel to the engine.

  1. WARNING:
    WARNING:The clutch disc and clutch pressure plate are heavy and may fall if not held when the bolts are removed. Failure to follow these instructions may result in personal injury.
    CAUTION:
    CAUTION:Loosen the bolts evenly to prevent pressure plate damage.
    Remove the bolts, clutch pressure plate and clutch disc.

  1. Remove the flywheel.

  1. Remove the special tool.

  1. Remove rear cover plates and dowels.

  1. Using the special tool, remove the crankshaft rear seal.

  1. Inspect the crankshaft rear oil seal area.

  1. NOTE:
    NOTE:Install a new pilot bearing only if it is damaged.
    Use the special tool to remove the pilot bearing.
    1. Install the special tool.
    1. Remove the pilot bearing.
  1. Mount the engine on a suitable engine stand.

  1. Remove the bolt and the oil level indicator and tube.

  1. Remove the six bolts and three nuts and remove the exhaust manifold.
    • Discard the gasket.

  1. Remove the power steering pump bracket.

  1. Remove the A/C compressor bracket.

  1. Remove the coolant tube.
    • Remove the bolt and nut.
    • Disconnect the hose.

  1. Remove the crankshaft position (CKP) sensor.

  1. Remove the crankcase vent oil separator.
    1. Disconnect the positive crankcase ventilation (PCV) valve.
    1. Remove the bolts and remove the separator.

        2. 1. Discard the gasket.

  1. Remove the coolant tube.
    • Remove the bolt.
    • Disconnect the hose.

  1. Remove the bolt and remove the crankshaft pulley.

  1. Remove the accessory drive belt idler pulley.

  1. Remove the lower timing belt cover.

  1. Remove the water pump pulley.

  1. Remove the lower engine mount bracket.

  1. Disconnect the wire harness.

  1. Remove the upper timing belt cover.

  1. Remove the timing belt tensioner and remove and discard the timing belt.

  1. Remove the water pump adapter.

  1. Remove the timing belt idler pulley.

  1. Remove the ignition wires from the spark plugs.

  1. Disconnect the wire harness and position aside.

  1. Remove the valve cover.
    • Remove the studbolts.
    • Remove the bolts.

  1. CAUTION:
    CAUTION:The camshaft alignment tool is not recommended to hold the camshafts in place when removing or tightening the bolts. Damage to camshaft may result.
    NOTE:
    NOTE:Use an open-end wrench to keep each camshaft from rotating.
    Remove the bolts and the camshaft timing sprockets.

  1. CAUTION:
    CAUTION:Cylinder head camshaft journal caps are numbered on the outside flats to make sure that they are assembled in their original positions. Failure to do so may result in engine damage.
    Remove the camshafts.
    • Loosen the camshaft journal cap bolts in several two-turn passes in the sequence shown.
    • Remove the bolts.
    • Remove the caps.

  1. CAUTION:
    CAUTION:If the camshaft and valve tappets are to be reused, mark the location of the valve tappets to make sure that they are assembled in their original positions.
    Remove the valve tappets from the cylinder head.

  1. Remove the inner timing belt cover.

  1. Remove the generator.

  1. Remove the generator bracket.
  1. Disconnect the following electrical connectors and remove the fuel charging wiring harness from the engine:
    1. cylinder temperature sensor
    1. throttle position sensor
    1. wiring harness to vehicle
    1. idle air control valve
    1. camshaft position sensor
    1. fuel injectors

  1. Disconnect EGR tube fitting.

  1. Remove the EGR tube.

  1. NOTE:
    NOTE:The coil is removed from the picture for clarity.
    Remove the coil and bracket assembly.

  1. Remove the thermostat housing.
    • Inspect and install a new O-ring seal if damaged.

  1. Remove the PCV tube.

  1. NOTE:
    NOTE:Illustration shown with throttle body and fuel supply manifold removed for clarity.
    Remove the intake manifold.
    • Remove the two nuts and five bolts in the sequence shown.

  1. Remove the oil pressure sensor.

  1. Remove the block heater if equipped.

  1. Remove the knock sensor.

  1. Remove the oil cooler.

  1. Remove the crankshaft sprocket and timing belt guide.

  1. CAUTION:
    CAUTION:The bolts are torque-to-yield, new bolts must be installed or engine damage can occur.
    Remove the cylinder head using the sequence shown.
    • Discard the gasket.
    • Discard the bolts.

  1. Remove the 17 bolts and the oil pan.

  1. Remove the bolts and the oil pump cover and screen.
    • Carefully remove and discard the oil pump inlet tube gasket.

  1. Remove the lower cylinder block and the gasket.

  1. Remove the seven bolts and the oil pump.
    • Remove the oil pump to cylinder block gasket.

  1. Remove the rear main oil seal retainer assembly and discard the gasket.

  1. CAUTION:
    CAUTION:The connecting rods and connecting rod caps must be correctly oriented and, the interlocking tangs on the same side of the connecting rod or possible engine damage may occur.
    CAUTION:
    CAUTION:The connecting rod bolts are torque-to-yield. Discard the connecting rod bolts.
    Remove the four connecting rod caps.

  1. If the connecting rod bearings are to be reused, each one must be identified so that it can be installed in its original location. Remove the four upper and four lower connecting rod bearings.

  1. Use a suitable tool and remove the cylinder ridge.

  1. Remove the four piston and connecting rod assemblies.

  1. CAUTION:
    CAUTION:Make sure the main bearing caps are installed in their original position or possible engine damage may occur.
    Remove the bolts and remove the crankshaft main bearing caps and bearings.

  1. Remove the crankshaft.

  1. Remove the upper crankshaft main bearings.

  1. Remove the Woodruff key.

Disassembly and Assembly of Subassemblies > < Engine - Vehicles With: Manual Transaxle