Disassembling the Duratec 8V 1.6L engine

Special tool

	Universal Flange Holding Wrench 205-072 (15-030A)
	Engine lift bracket 303-122 (21-068A)
	Socket wrench for cylinder head bolts 303-392 (21-167)
	Booth 303-435 (21-187)
	Support bracket for 303-435 303-435-06 (21-031B)
	Support plate for 303-435-06 303-435-11 (21-146C)

1. Remove the exhaust system heat shield.



2. Remove the exhaust manifold.

• Remove the mounting nuts in the sequence shown.
• Discard the gasket as it is no longer needed.

3. Using special tools, install the engine on the stand.




4. Remove the special tool.



5. Remove the front engine mount bracket.



6. Remove the generator.



7. Remove the generator bracket.




8. Drain the engine oil. 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 engine coolant temperature (ECT) sensor connectors.




12. Remove the intake manifold.



13. Remove the cylinder head cover.



14. Remove the crankshaft position (CKP) sensor and oil pressure switch.



15. Remove the oil filter adapter. Discard the gasket as it is no longer needed.




16. Remove the coolant circulation control unit.



17. Remove the hydraulic timing chain tensioner.



18. Remove the oil level indicator dipstick tube.



19.

CAUTION: Using a suitable piece of wire, tie the timing chain and camshaft sprocket to the cylinder head to prevent them from falling into the cylinder block.

Using a special tool, remove the camshaft sprocket.



20.

NOTE: Loosen the cylinder head bolts in the sequence shown.

Using a special tool, remove the cylinder head. Discard the gasket as it is no longer needed.



21. Remove the water pump pulley.



22. Remove the water pump. Discard the gasket as it is no longer needed.



23.

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

Remove the crankshaft pulley bolt.



24. Remove the flywheel.



25. Remove the adapter plate.



26.

CAUTION: Remove the oil pan by pulling it downward to prevent oil sludge or abrasive particles from entering the engine.

Remove the oil pan. Discard the gasket as it is no longer needed.



27. Remove the rear oil seal holder. Discard the rear oil seal holder as it is no longer needed.



28. Remove the oil pump intake pipe.



29.

CAUTION: Remove the oil pump only together with the crankshaft pulley.

CAUTION: After removing the oil pump assembly, do not remove the crankshaft pulley from the oil pump.

Remove the oil pump assembly.

• Discard the oil pump gasket as it is no longer needed.
• Discard the sealed oil pump mounting bolts as they are no longer needed.

30. Remove the timing chain.

31. Remove the timing chain guide, timing chain tensioner lever and crankshaft sprocket.



32. Remove the oil pan deflector.



33.

NOTE: Do not damage the cylinder liner surfaces. Save the connecting rods, bearing shells and bearing caps for later assembly.

Remove the pistons.



34.

NOTE: Save bearing caps and bearing shells for later assembly.

Remove the crankshaft.



35.

NOTE: Save the thrust washers for later assembly.

Remove the thrust half rings.



36.

NOTE: Save the bearing shells for later assembly.

Remove the main bearing shells.