Ford Workshop Service and Repair Manuals

Universal Flange Holding Wrench

205-072 (15-030A)

Lifting Bracket, Engine

303-122 (21-068A)

Socket, Cylinder Head Bolt

303-392 (21-167)

Mounting Stand

303-435 (21-187)

Mounting Bracket for 303-435

303-435-06 (21-031B)

Mounting Plate for 303-435-06

303-435-11 (21-146C)

1. Remove the exhaust manifold heat shield.

2. Remove the exhaust manifold.
   • Discard the gasket and the nuts.

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

4. Remove the special tool.

5. Remove the engine front mount bracket.

6. Remove the generator.

7. Remove the generator bracket.

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

9. Install the oil drain plug.

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

11. Disconnect the camshaft position (CMP) sensor and the engine coolant temperature (ECT) sensor electrical connectors.

12. Remove the intake manifold.

13. Remove the valve cover.

14. Remove the knock sensor (KS).

15. Remove the oil pressure switch.

16. Remove the crankshaft position (CKP) sensor.

17. Remove the oil filter adaptor.
    • Discard the gasket.

18. Remove the coolant flow control housing.

19. Remove the timing chain hydraulic tensioner.

20. Remove the oil level indicator tube.

21. 

    CAUTION:Using a suitable piece of wire, secure the timing chain and camshaft sprocket to the cylinder head to prevent it from dropping into the cylinder block.
    Using the special tool, remove the camshaft sprocket.

22. 

    NOTE:Loosen the cylinder head bolts in the sequence shown.
    Using the special tool, remove the cylinder head.
    • Discard the gasket.

23. Remove the water pump pulley.

24. Remove the water pump.
    • Discard the gasket.

25. 

    CAUTION:Do not remove the crankshaft pulley at this stage.
    Remove the crankshaft pulley retaining bolt.

26. Remove the flywheel.

27. Remove the adaptor plate.

28. 

    CAUTION:Remove the oil pan by pulling it downwards to prevent oil deposits or abraded particles from entering the engine.
    Remove the oil pan.
    • Discard the gasket.

29. Remove the cranshaft rear seal carrier.
    • Discard the crankshaft rear seal carrier.

30. Remove the oil pump pick-up pipe.

31. 

    CAUTION:Only remove the oil pump together with the crankshaft pulley.
    

    CAUTION:Do not remove the crankshaft pulley from the oil pump after removal of the oil pump assembly.
    Remove the oil pump assembly.
    • Discard the oil pump gasket.
    • Discard the pre-sealed oil pump retaining bolts.

32. Remove the timing chain.

33. Remove the timing chain guide, the timing chain tensioner arm and the crankshaft sprocket.

34. Remove the oil pan baffle.

35. 

    NOTE:Do not damage the cylinder liner surfaces. Keep the connecting rods, bearing shells and bearing caps in order for assembly.
    Remove the pistons.

36. 

    NOTE:Keep the bearing caps and bearing shells in order for assembly.
    Remove the crankshaft.

37. 

    NOTE:Keep the thrust half-washers in order for assembly.
    Remove the thrust half-washers.

38. 

    NOTE:Keep the bearing shells in order for assembly.
    Remove the crankshaft bearing shells.