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Home › Ford › 2002 › Focus SVT › Repair and Diagnosis › External Pages › Different variant/trim › Section 2 (Engine - 2.0L SPI) › Disassembly › Engine › Special Tool(s)

Special Tool(s)

WARNING: This page is about a different variant/trim than selected.
Fig 1: Removing Special Tools
G03432344Courtesy of FORD MOTOR CO.
  1. Disconnect and remove the following.
    • Vacuum hoses
    • Coolant hoses and tubes
    • Positive crankcase ventilation and fresh air hoses
  2. Remove the clutch (if equipped). For additional information, refer to CLUTCHES article .
  3. Remove the flywheel.
    • Install the special tool.
    • Remove the bolts.
      Fig 2: Removing Flywheel
      G03432345Courtesy of FORD MOTOR CO.
  4. Attach the engine to stand.
  5. Disconnect the exhaust gas recirculation tube from the EGR valve.
    Fig 3: Disconnecting Exhaust Gas Recirculation Tube From EGR Valve
    G03432346Courtesy of FORD MOTOR CO.
  6. Disconnect the EGR tube from the exhaust manifold.
    Fig 4: Disconnecting EGR Tube From Exhaust Manifold
    G03432347Courtesy of FORD MOTOR CO.
  7. Remove the oil lever indicator tube.
    Fig 5: Removing Oil Lever Indicator Tube
    G03432348Courtesy of FORD MOTOR CO.
  8. Disconnect the crankshaft position (CKP) sensor electrical connector.
    Fig 6: Disconnecting Crankshaft Position (CKP) Sensor Electrical Connector
    G03432349Courtesy of FORD MOTOR CO.
  9. Disconnect the fuel injectors electrical connectors.
    Fig 7: Disconnecting Fuel Injectors Electrical Connectors
    G03432350Courtesy of FORD MOTOR CO.
  10. Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor electrical connectors.
    Fig 8: Disconnecting Idle Air Control (IAC) Valve And Throttle Position (TP) Sensor Electrical Connectors
    G03432351Courtesy of FORD MOTOR CO.
  11. Disconnect the oil pressure sender unit and the knock sensor.
    Fig 9: Disconnecting Oil Pressure Sender Unit And Knock Sensor
    G03432352Courtesy of FORD MOTOR CO.
  12. Disconnect the fuel pressure sensor electrical connector.
    Fig 10: Disconnecting Fuel Pressure Sensor Electrical Connector
    G03432353Courtesy of FORD MOTOR CO.
  13. Disconnect the electrical connectors.
    • Camshaft position (CMP) sensor
    • Intake manifold runner control (IMRC)
    • Radio interference capacitor
    • Ignition coil
    • Water temperature indicator sender unit
      Fig 11: Disconnecting Electrical Connectors
      G03432354Courtesy of FORD MOTOR CO.
  14. Detach the retainers and remove the fuel charge wiring harness.
    Fig 12: Removing Fuel Charge Wiring Harness
    G03432355Courtesy of FORD MOTOR CO.
  15. Remove the intake manifold bracket.
    Fig 13: Removing Intake Manifold Bracket
    G03432356Courtesy of FORD MOTOR CO.
    16. CAUTION: Use care not to drop any components.
  16. Remove the intake manifold and IMRC.
    • Discard the gaskets.
      Fig 14: Removing Intake Manifold And IMRC
      G03432357Courtesy of FORD MOTOR CO.
    17. CAUTION: Do not pull on the ignition wires directly, as wires may separate from the connector inside the boot.
    Fig 15: Disconnecting Spark Plug Wires
    G03432358Courtesy of FORD MOTOR CO.
  17. Disconnect the spark plug wires.
  18. Remove the ignition coil, ignition coil bracket and wires as one assembly.
    Fig 16: Removing Ignition Coil, Ignition Coil Bracket And Wires
    G03432359Courtesy of FORD MOTOR CO.
  19. Remove the oil filter.
    Fig 17: Removing Oil Filter
    G03432360Courtesy of FORD MOTOR CO.
  20. Remove the knock sensor.
    Fig 18: Removing Knock Sensor
    G03432361Courtesy of FORD MOTOR CO.
  21. Remove the oil pressure sender unit.
    Fig 19: Removing Oil Pressure Sender Unit
    G03432362Courtesy of FORD MOTOR CO.
  22. Remove the CKP sensor.
    Fig 20: Removing CKP Sensor
    G03432363Courtesy of FORD MOTOR CO.
  23. Remove the generator.
    Fig 21: Removing Generator
    G03432364Courtesy of FORD MOTOR CO.
  24. Remove the accessory drive belt bracket.
    Fig 22: Removing Accessory Drive Belt Bracket
    G03432365Courtesy of FORD MOTOR CO.
    25. NOTE: Remove the nuts evenly.
  25. Remove the exhaust manifold.
    • Discard the gasket.
      Fig 23: Removing Exhaust Manifold
      G03432366Courtesy of FORD MOTOR CO.
  26. Remove the water outlet connection, thermostat and gasket.
    Fig 24: Removing Water Outlet Connection, Thermostat And Gasket
    G03432367Courtesy of FORD MOTOR CO.
    27. NOTE: If an original spark plug is reused, install it in the same cylinder from which it was removed. New spark plugs may be installed in any cylinder.
    Fig 25: Removing Spark Plugs
    G03432368Courtesy of FORD MOTOR CO.
  27. Remove the spark plugs.
    28. NOTE: Using the special tool, hold the crankshaft pulley.
    Fig 26: Removing Crankshaft Pulley
    G03432369Courtesy of FORD MOTOR CO.
  28. Remove the crankshaft pulley.
  29. Remove the timing belt cover.
    Fig 27: Removing Timing Belt Cover
    G03432370Courtesy of FORD MOTOR CO.
  30. Remove the upper timing belt cover.
    Fig 28: Removing Upper Timing Belt Cover
    G03432371Courtesy of FORD MOTOR CO.
  31. Align the timing marks.
    Fig 29: Aligning Timing Marks
    G03432372Courtesy of FORD MOTOR CO.
  32. Remove the timing belt.
    1. Use an 8 mm Allen key and turn counterclockwise one-fourth turn.
    2. Insert a 3 mm (1/8 inch) drill bit to lock the timing belt tensioner in place.
    3. Remove the timing belt.
      Fig 30: Removing Timing Belt
      G03432373Courtesy of FORD MOTOR CO.
  33. Remove the timing belt tensioner.
    1. Remove the bolt.
    2. Remove the tensioner.
      Fig 31: Removing Timing Belt Tensioner
      G03432374Courtesy of FORD MOTOR CO.
  34. Remove the water pump.
    • Discard the gasket.
      Fig 32: Removing Water Pump
      G03432375Courtesy of FORD MOTOR CO.
  35. Remove the crankshaft sprocket and the timing belt guide.
    Fig 33: Removing Crankshaft Sprocket And Timing Belt Guide
    G03432376Courtesy of FORD MOTOR CO.
  36. Remove the valve cover.
    Fig 34: Removing Valve Cover
    G03432377Courtesy of FORD MOTOR CO.
    37. NOTE: Remove the bolts evenly and sequentially.
  37. Remove the cylinder head.
    • Discard the gasket.
      Fig 35: Identifying Removal Sequence Of Cylinder Head Bolts
      G03432378Courtesy of FORD MOTOR CO.
    38. NOTE: Mark location of the two stud bolts.
  38. Remove the oil pan.
    • Discard the gasket.
      Fig 36: Removing Oil Pan
      G03432379Courtesy of FORD MOTOR CO.
  39. Remove the oil pump screen cover and tube.
    • Discard the gasket.
      Fig 37: Removing Oil Pump Screen Cover And Tube
      G03432380Courtesy of FORD MOTOR CO.
  40. Remove the oil baffle.
    Fig 38: Removing Oil Baffle
    G03432381Courtesy of FORD MOTOR CO.
  41. Remove the oil pump.
    • Discard the gasket.
      Fig 39: Removing Oil Pump
      G03432382Courtesy of FORD MOTOR CO.
  42. Remove and discard the oil pump seal.
    Fig 40: Removing Oil Pump Seal
    G03432383Courtesy of FORD MOTOR CO.
  43. Remove the crankshaft rear seal retainer.
    • Discard the gasket.
      Fig 41: Removing Crankshaft Rear Seal Retainer
      G03432384Courtesy of FORD MOTOR CO.
  44. Remove the four connection rod caps.
    Fig 42: Removing Connecting Rod Caps
    G03432385Courtesy of FORD MOTOR CO.
  45. Install a short length of rubber tubing over the connection rod bolts to avoid damage to the crankcase journals.
    Fig 43: Installing Short Length Of Rubber Tubing Over Connecting Rod Bolts
    G03432386Courtesy of FORD MOTOR CO.
  46. Inspect the top of each cylinder bore before removing the piston. If a ridge has formed at the top of the cylinder, the ridge must be removed before the pistons can be removed. Remove the ridge as follows:
    • Turn the crankshaft clockwise until the piston is at the bottom of its cylinder bore.
    • Place a clean ship cloth over the piston head to collect cuttings.
    • Using the special tool 303-016 (T64L-6011-EA), remove the ridge. Never cut into the ring travel area more than 0.8 mm (1/32 in) when removing the ridge.
  47. Remove the pistons and the connection rod assemblies.
    Fig 44: Removing Pistons And Connecting Rod Assemblies
    G03432387Courtesy of FORD MOTOR CO.
    48. NOTE: The crankshaft main bearings are precision selective fit. Check bearing clearances or select fit a new crankshaft main bearing. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION article .
    Fig 45: Removing Main Bearing Caps And Lower Crankshaft Main Bearings
    G03432388Courtesy of FORD MOTOR CO.
  48. Remove the five main bearing caps and the lower crankshaft main bearings.
  49. Remove the crankshaft.
    Fig 46: Removing Crankshaft
    G03432389Courtesy of FORD MOTOR CO.
  50. Remove the bearings.
    1. Upper crankshaft main bearings.
    2. Crankshaft thrust main bearing.
      Fig 47: Removing Upper Crankshaft Main Bearings And Crankshaft Thrust Main Bearing
      G03432390Courtesy of FORD MOTOR CO.
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