Ford Workshop Service and Repair Manuals

Universal Flange Holding Wrench

205-072

Adapter for 205-072

205-072-01

Adapter for 205-072

205-072-02

Lifting Bracket, Engine

303-122

Locking Tool, Flywheel

303-254

Remover/Installer, Hose Clamp

303-397

Mounting Stand

303-435

Mounting Bracket for 303-435

303-435-06

Mounting Plate for 303-435-06

303-435-11A

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 pan drain plug seal for damage. Install a new drain plug and seal if required.
   Install the drain plug.

5. Remove the exhaust manifold retaining bracket.

6. Detach electrical connector bracket from the thermostat housing.

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

8. Remove the intake manifold.

9. Using the special tool, disconnect the coolant hose.

10. Remove the ignition coil-on-plug.

11. Remove the valve cover.

12. Remove the accessory drive belt tensioner.

13. Remove the generator.

14. Remove the coolant pump pulley.

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

16. Remove the engine front cover.

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

18. 

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

19. Remove the timing chain guides.

20. Remove the timing chain tensioner.

21. Remove the oil pump chain guide (if equipped).

22. Remove the oil pump chain tensioner.

23. Using the special tool, loosen the oil pump sprocket retaining bolt.

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

25. Remove the front friction washer.
    • Discard the friction washer.

26. Remove the crankshaft sprocket.

27. Remove the rear friction washer.
    • Discard the friction washer.

28. 

    CAUTION:Keep the camshaft bearing caps, valve tappets and the camshafts in order for installation.
    

    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.

29. 

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

30. Remove the coolant pump.
    • Discard the O-ring.

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

32. Remove the knock sensor (KS) for cylinder 1 and 2 and for cylinder 3 and 4.

33. Remove the KS (if equipped).

34. Remove the crankcase ventilation oil separator.

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

36. Remove the clutch disc and pressure plate.
    For additional information, refer to: Clutch Disc and Pressure Plate (308-01A Clutch - Vehicles With: 5-Speed Manual Transmission (iB5), Removal and Installation) /
    Clutch Disc and Pressure Plate (308-01 Clutch - Vehicles With: 5-Speed Manual Transmission (MTX-75), Removal and Installation).
    

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

38. Remove the flywheel.
    • Discard the bolts.

39. Remove the special tool.

40. 

    NOTE:Remove the oil pan by pulling it downwards to prevent oil deposits or abraded particles from entering the engine.
    Remove the oil pan.

41. Remove the crankshaft rear seal carrier.
    • Discard the seal carrier.
    • Discard the gasket.

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