Ford Workshop Service and Repair Manuals

Universal Flange Holding Wrench

205-072 (15-030A)

Adaptor for 205-072

205-072-01

Adapter for 205-072

205-072-02 (15-030A-02)

Lifting Bracket, Engine

303-122 (21-068A)

Locking Tool, Flywheel

303-254 (21-135)

Remover/Installer, Hose Clamp

303-397 (24-003)

Mounting Stand

303-435 (21-187)

Mounting Bracket for 303-435

303-435-06 (21-031B)

Mounting Plate for 303-435-06

303-435-11A (21-146D)

Socket, Spark Plug

303-499 (21-202)

1. Using the special tools, mount the engine to the mounting stand.

2. Remove the special tool.

3. Drain the engine.
   • Allow the oil to drain into a suitable container.

4. 

   NOTE:Inspect the oil drain plug seal for damage. Install a new drain plug and seal if necessary.
   Install the drain plug.

5. Remove the oil level indicator and oil level indicator tube.

6. Remove the exhaust manifold upper heat shield.

7. Remove the exhaust manifold lower heat shield.

8. Remove the exhaust manifold retaining bracket retaining bolts.

9. Remove the exhaust gas recirculation (EGR) valve to exhaust manifold pipe.
   • Discard the gaskets.

10. Remove the exhaust manifold.
    • Discard the gasket.

11. Remove the EGR pipe.
    • Discard the gaskets.

12. Using the special tool, disconnect the coolant hose from the throttle body.

13. Remove the power steering pump.

14. Remove the intake manifold retaining bolts.

15. Disconnect the positive crankcase ventilation (PCV) hose from the intake manifold.

16. Remove the fuel return line.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).
    

17. Detach the high-pressure fuel supply line from the fuel pump.

18. Remove the fuel pump.
    • Discard the O-ring seal.

19. Remove the fuel pump tappet.

20. Remove the fuel pump drive assembly.
    • Discard the gasket.

21. Remove the ignition coils on plug.

22. Using the special tool, remove the spark plugs.

23. Remove the valve cover.

24. Using the special tool, disconnect the coolant hoses.

25. Remove the accessory drive belt idler pulley.

26. Remove the coolant pump pulley.

27. Using the special tools, prevent the crankshaft pulley from rotating and remove the crankshaft pulley.

28. Remove the crankshaft position (CKP) sensor.

29. Remove the CKP sensor bracket.

30. Remove the engine front cover.

31. Detension the timing chain.
    1. Unlock the timing chain tensioner ratchet.
    2. Apply pressure to the timing chain guide.
    3. Lock the timing chain tensioner with a suitable pin punch.

32. 

    NOTE:Hold the camshafts by the hexagon with an open-ended wrench to prevent them from rotating.
    Remove the camshaft sprockets and the timing chain.

33. Remove the timing chain guides.

34. Remove the timing chain tensioner.

35. Remove the oil pump chain guide.

36. Remove the oil pump chain tensioner.

37. Using the special tools, loosen the oil pump sprocket retaining bolt.

38. Remove the oil pump chain.
    1. Remove the oil pump sprocket retaining bolt.
    2. Remove the oil pump chain and the oil pump sprocket.

39. Remove the front friction washer (if equipped).
    • Discard the friction washer.

40. Remove the crankshaft sprocket.

41. Remove the rear friction washer (if equipped).
    • Discard the friction washer.

42. 

    CAUTION:Remove the camshaft bearing caps in the sequence shown.
    

    NOTE:Working in several stages, release each camshaft bearing cap retaining bolt two turns at a time.
    Remove the camshaft bearing caps.
    • Remove the camshafts.
    • Remove the valve tappets.

43. 

    CAUTION:Remove the cylinder head bolts in the sequence shown.
    Remove the cylinder head.
    • Discard the gasket.

44. Remove the knock sensors (KS).

45. Remove the coolant pump.
    • Discard the O-ring seal.

46. Remove the thermostat housing.
    • Discard the gasket.

47. Remove the crankcase vent oil separator.

48. Remove the oil filter adapter.
    • Discard the gasket.

49. Remove the clutch disc and pressure plate.
    For additional information, refer to: Clutch Disc and Pressure Plate (308-01B Clutch - Vehicles With: 6-Speed Manual Transmission (MMT6), Removal and Installation).
    

50. Using the special tool, lock the flywheel in position.

51. Remove the flywheel.
    • Discard the bolts.

52. Remove the special tool.

53. Remove the oil pan.

54. Remove the crankshaft rear seal carrier.
    • Discard the seal carrier.

55. Remove the oil pump.
    • Discard the gasket.