Removal

NOTE: Ford does not provide camshaft gear timing marks, or information to perform timing belt service without the special tools shown in this procedure.

Cylinder Head

Special Tools:

Special Tools

Removal

CAUTION: The maximum amount by which the engine management system will adjust the camshaft timing (VCT control unit) is limited to two degrees. As a result of this an extremely high degree of accuracy is required for any work which affects the valve timing.

NOTE: The locations of engine mountings and engine support insulators are described looking from the transaxle to the engine

NOTE: Operation steps which only apply to certain model variants and therefore do not apply to all vehicles are clearly marked

1. Disconnect the battery ground cable

2. WARNING: When releasing the system pressure, cover the coolant expansion tank cup with a thick cloth to prevent the possibility of scalding. Failure to follow these instruction will result in personal injury.

Release the coolant expansion tank cap
3. Loosen the RH front wheel nuts
4. Raise and support the vehicle.
- Remove the right-hand front wheel.





5. Remove the radiator splash shield and drain the coolant.
1 Remove the six bolts.
2 Unscrew the radiator drain plug.





6. Remove the power steering pump lower bolts.





7. Disconnect the brake booster line and the crankcase ventilation hose from the intake manifold.





8. Disconnect the oil pressure switch and the Knock Sensor (KS) electrical connector
9. Lower the vehicle.





10. Remove the intake pipe.
1 Disconnect the Mass Air Flow (MAF) sensor electrical connector.
2 Disconnect the Intake Air Temperature (IAT) sensor electrical connector.
3 Remove the bolt and the two nuts.





11. Remove the Air Cleaner (ACL).
1 Disconnect the crankcase ventilation hose.
2 Disconnect the intake hose.





12. Disconnect the speed control cable.
1 Disconnect the cable from throttle valve.
2 Move the cable up and down and pull it out of the retaining bushing.
3 Press the retaining bushing out of the bracket.





13. Disconnect the throttle cable.
1 Remove the plastic clip and position the throttle cable to one side.
2 Unhook the cable.





14. Disconnect the wiring harness rail and the vacuum hoses.
- Disconnect the cylinder head wiring harness electrical connector.
- Disconnect the vacuum hoses.
- Unscrew the upper wiring harness rail bolts on the intake manifold.





15. Disconnect the starter motor positive lead.
- Remove the under shield.

CAUTION: Do not bend the fusible element when undoing the nut as there is a risk of it breaking.

- Unscrew the nut.





16. Disconnect the electrical connectors.
1 Radio interference suppressor.
2 Ignition coil.
3 Engine Coolant Temperature (ECT) sensor.
4 Power Steering Pressure (PSP) switch.
- Position the wiring to one side.





17. Remove the thermostat housing.
1 Disconnect the Camshaft Position (CMP) sensor electrical connector.
2 Disconnect the coolant hoses and position to one side.
3 Unscrew the bolts.





18. Detach the Positive Crankcase Ventilation (PCV) line.





19. Remove the exhaust manifold heat shield.
1 Unscrew the upper bolts.
- Remove the coolant hose bracket and the engine lifting eye, and pull out the engine oil level indicator tube.
2 Remove the coolant hose bracket clamp.
3 Remove the lower bolts.





20. Disconnect the Three-Way Catalytic Converter (TWC) from the exhaust manifold.
- Disconnect the Heated Oxygen Sensor (HO2S) electrical connector.





21. Remove the pulley cover.





22. Detach the power steering pump.
1 Remove the power steering pump bracket from the cylinder head.
2 Remove the upper power steering pump bolts.





23. Remove the generator.
1 Disconnect the generator electrical connectors.
2 Remove the bolts.





24. Remove the generator bracket
25. Remove the timing belt.





26. Remove the camshaft pulleys.
- Remove the timing belt.
1 Remove the blanking plug from the exhaust camshaft pulley.

NOTE: Hold the camshaft by the hexagon with an open-ended wrench to stop it from turning.

2 Remove the exhaust camshaft pulley.
3 Remove the intake camshaft pulley.





27. Remove the bolts from the variable camshaft timing (VCT) oil feed flange and the upper part of the engine front cover.





28. NOTE: Working evenly in several stages, unscrew each bolt two turns at a time.

Loosening sequence of the camshaft bearing caps.





29. NOTE: Loosening sequence

Remove the camshafts.
1 Remove the camshaft bearing caps.
2 Remove the intake camshaft.
3 Remove the exhaust camshaft with the VCT control unit.
- Remove the valve tappets.





30. WARNING: Wait until the cylinder head has cooled down to ambient temperature. Failure to follow this instruction may result in personal injury.

NOTE: Loosening sequence

Remove the cylinder head bolts.
31. Remove the cylinder head.
- Using the Workshop hoist hook it into the engine lifting eyes; lift off the cylinder head and place it on clean Wooden blocks.
- Discard the cylinder head gasket.