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Section 1507 (Engine - 2.3L - (Hybrid)): Disassembly: Engine

WARNING: This page is about a different car, the 2006 Mercury Mariner and 2006 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL(S)

G04619061Courtesy of FORD MOTOR CO.
 Heavy Duty Floor Crane
014-00071 or equivalent
G04619062Courtesy of FORD MOTOR CO.
 Spreader Bar
303-D089 (D93P-6001-A3) or equivalent
G04619063Courtesy of FORD MOTOR CO.
 Engine Stand
014-00232 or equivalent
G04619064Courtesy of FORD MOTOR CO.
 Alignment Plate, Camshaft
303-465 (T94P-6256-CH)
G04619065Courtesy of FORD MOTOR CO.
 Timing Peg, Crankshaft
303-507
G04619066Courtesy of FORD MOTOR CO.
 Holding Fixture, Drive Pinion Flange
205-126 (T78P-4851-A)
G04619067Courtesy of FORD MOTOR CO.
 Adapter for 205-126
(205-072-02)
G04619068Courtesy of FORD MOTOR CO.
 Remover, Oil Seal
303-409 (T92C-6700-CH)
CAUTION:
  1. Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley bolt. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.
  2. During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, can cause engine failure.
  3. Due to the precision fit and timing of the balancer shaft assembly, it cannot be removed from the engine block.
NOTE: For additional information, refer to the exploded views under engine assembly.
  1. Remove the 6 bolts and the flywheel.
    Fig 1: Locating Flywheel Bolts
    G04619069Courtesy of FORD MOTOR CO.
  2. Mount the engine on a suitable stand.
  3. Disconnect the crankshaft position (CKP) sensor electrical connector.
    Fig 2: Locating Crankshaft Position (CKP) Sensor Electrical Connector
    G04619070Courtesy of FORD MOTOR CO.
  4. Remove the bolt and the engine wiring harness connector bracket.
    Fig 3: Locating Engine Wiring Harness Connector Bracket
    G04619071Courtesy of FORD MOTOR CO.
  5. Detach the engine wiring harness pin-type retainer.
    Fig 4: Locating Engine Wiring Harness Pin-Type Retainer
    G04619072Courtesy of FORD MOTOR CO.
  6. Remove the 3 bolts and the accessory drive belt tensioner.
    Fig 5: Locating Accessory Drive Belt Tensioner
    G04619073Courtesy of FORD MOTOR CO.
  7. Disconnect the coil-on-plug and camshaft position (CMP) sensor electrical connectors.
    Fig 6: Locating Coil-On-Plug And Camshaft Position (CMP) Sensor Electrical Connectors
    G04619074Courtesy of FORD MOTOR CO.
  8. Position the rubber boot aside and disconnect the cylinder head temperature (CHT) sensor electrical connector.
    Fig 7: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector
    G04619075Courtesy of FORD MOTOR CO.
  9. If equipped, disconnect the block heater electrical connector.
    Fig 8: Locating Block Heater Electrical Connector
    G04619076Courtesy of FORD MOTOR CO.
  10. Disconnect the radio ignition interference capacitor electrical connector.
    Fig 9: Locating Radio Ignition Interference Capacitor Electrical Connector
    G04619077Courtesy of FORD MOTOR CO.
  11. Disconnect the exhaust gas recirculation (EGR) valve electrical connector and remove the engine control wiring harness from the engine.
    Fig 10: Locating Exhaust Gas Recirculation (EGR) Valve Electrical Connector
    G04619078Courtesy of FORD MOTOR CO.
  12. Remove the 3 bolts and the coolant pump pulley.
    Fig 11: Locating Coolant Pump Pulley Bolts
    G03897969Courtesy of FORD MOTOR CO.
  13. Remove the 3 bolts and the coolant pump.
    Fig 12: Locating Coolant Pump Bolts
    G03897970Courtesy of FORD MOTOR CO.
  14. Disconnect the coolant hose.
    Fig 13: Locating Coolant Hose
    G04619081Courtesy of FORD MOTOR CO.
  15. Remove the 3 bolts and the thermostat housing.
    Fig 14: Locating Thermostat Housing Bolts
    G04619082Courtesy of FORD MOTOR CO.
  16. Disconnect the coolant hose.
    Fig 15: Locating Coolant Hose
    G04619083Courtesy of FORD MOTOR CO.
  17. Remove the bolt and the knock sensor (KS).
    Fig 16: Locating Knock Sensor Bolt
    G04619084Courtesy of FORD MOTOR CO.
  18. Remove the 8 bolts and the crankcase vent oil separator.
    Fig 17: Locating Crankcase Vent Oil Separator And Bolts
    G04619085Courtesy of FORD MOTOR CO.
  19. Remove the 4 bolts and the oil filter adapter. Discard the gasket.
    Fig 18: Locating Oil Filter Adapter
    G04619086Courtesy of FORD MOTOR CO.
  20. Disconnect and remove the coolant hoses.
    Fig 19: Locating Coolant Hoses
    G04619087Courtesy of FORD MOTOR CO.
  21. If equipped, remove the block heater.
    Fig 20: Locating Block Heater
    G04619088Courtesy of FORD MOTOR CO.
  22. Remove the engine cover studs.
    Fig 21: Locating Engine Cover Studs
    G04619089Courtesy of FORD MOTOR CO.
  23. Remove the crankcase vent tube and the coil-on-plugs.
    Fig 22: Locating Crankcase Vent Tube & Coil-On-Plugs
    G04619090Courtesy of FORD MOTOR CO.
    24. CAUTION: Only use hand tools when removing or installing the spark plugs, damage can occur to the cylinder head or spark plug.
  24. Remove the spark plugs and the CHT sensor.
    • Discard the CHT sensor.
      Fig 23: Locating Spark Plugs & CHT Sensor
      G04619091Courtesy of FORD MOTOR CO.
  25. Remove the bolts and the valve cover.
    Fig 24: Locating Valve Cover Bolts
    G04619092Courtesy of FORD MOTOR CO.
    26. CAUTION: Failure to position the No. 1 piston at top dead center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only.
  26. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at TDC.
    • The hole in the crankshaft pulley should be in the 6 o'clock position.
      Fig 25: Identifying Hole In Crankshaft Pulley
      G04619093Courtesy of FORD MOTOR CO.
    27. CAUTION: The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
    NOTE: The camshaft timing slots are offset. If the special tool cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.
    Fig 26: Identifying Special Camshaft Tool (303-465)
    G03898006Courtesy of FORD MOTOR CO.
  27. Install the special tool in the slots on the rear of both camshafts.
  28. Remove the engine plug bolt.
    Fig 27: Locating Engine Plug Bolt
    G04319319Courtesy of FORD MOTOR CO.
    29. NOTE: The special tool will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during the crankshaft pulley removal and installation.
    Fig 28: Identifying Special Tool (303-507)
    G04617907Courtesy of FORD MOTOR CO.
  29. Install the special tool.
  30. Assemble the special tools using 4 hardened washers in the locations shown in Fig 29.
    Fig 29: Assembling Special Tools (205-072-02 And 205-126)
    G04619097Courtesy of FORD MOTOR CO.
    31. CAUTION:
    1. The crankshaft must remain in the TDC position during removal of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the special tool and the bolt should be removed using an air impact wrench (1/2-in drive minimum).
    2. If the crankshaft sprocket diamond washer comes off with the crankshaft pulley, it must be installed back onto the crankshaft.
  31. Using the special tools and an air impact wrench, remove the crankshaft pulley.
    • Remove and discard the crankshaft pulley bolt and washer.
    • Remove the crankshaft pulley.
      Fig 30: Removing Crankshaft Pulley Bolt & Washer Using Special Tools (205-126, 205-072-02)
      G04619098Courtesy of FORD MOTOR CO.
    32. CAUTION: Use care not to damage the engine front cover or the crankshaft when removing the seal.
    Fig 31: Removing Crankshaft Front Oil Seal Using Special Tool (303-409)
    G04619099Courtesy of FORD MOTOR CO.
  32. Using the special tool, remove the crankshaft front oil seal.
    33. NOTE: Whenever the CKP sensor is removed, a new one must be installed using the alignment tool supplied with the new part.
    Fig 32: Locating CKP Sensor
    G03898012Courtesy of FORD MOTOR CO.
  33. Remove and discard the CKP sensor.
  34. Remove the bolts and the engine front cover.
    Fig 33: Locating Engine Front Cover Bolts
    G03897743Courtesy of FORD MOTOR CO.
  35. Remove the timing chain tensioner.
    1. Compress the timing chain tensioner, and insert a paper clip into the hole to retain the tensioner.
    2. Remove the bolts and timing chain tensioner.
      Fig 34: Identifying Timing Chain Tensioner
      G04619102Courtesy of FORD MOTOR CO.
  36. Remove the RH timing chain guide.
    Fig 35: Locating RH Timing Chain Guide
    G03897778Courtesy of FORD MOTOR CO.
  37. Remove the timing chain.
    Fig 36: View Of Timing Chain
    G03897779Courtesy of FORD MOTOR CO.
  38. Remove the bolts and the LH timing chain guide.
    Fig 37: Identifying Bolts And LH Timing Chain Guide
    G03897780Courtesy of FORD MOTOR CO.
    39. CAUTION: Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation. Damage to the tool or the camshaft can occur.
    Fig 38: Locating Cam Holding Area And Sprocket Bolt
    G03897781Courtesy of FORD MOTOR CO.
  39. Using the flats on the camshaft to prevent camshaft rotation, remove the bolts and the camshaft sprockets.
  40. Remove the oil pump chain tensioner and guide.
    1. Release the tension on the tensioner spring.
    2. Remove the tensioner and the shoulder bolt.
    3. Remove the guide.
      Fig 39: Identifying Tensioner & Shoulder Bolt
      G04619107Courtesy of FORD MOTOR CO.
    41. NOTE:
    1. Remove the crankshaft sprocket diamond washers located in front of and behind the crankshaft sprocket.
    2. The oil pump chain sprocket must be held in place.
  41. Remove the oil pump chain and sprockets.
    1. Remove the bolt.
    2. Remove the chain and sprockets.
      Fig 40: Identifying Chain & Sprockets
      G04619108Courtesy of FORD MOTOR CO.
  42. Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.
    Fig 41: Locating Camshaft Lobe
    G03898791Courtesy of FORD MOTOR CO.
    43. CAUTION: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.
  43. Remove the camshafts from the engine.
    • Loosen the camshaft bearing bolts in the sequence shown in Fig 42, one turn at a time. Repeat until all the tension is released.
    • Remove the camshaft bearing caps.
    • Remove the camshafts.
      Fig 42: Identifying Loosening/Tightening Sequence Of Camshaft Bearing Bolts
      G03897808Courtesy of FORD MOTOR CO.
  44. Remove the cylinder head.
    • Remove and discard the cylinder head bolts.
    • Remove the cylinder head.
    • Remove and discard the cylinder head gasket.
      Fig 43: Locating Cylinder Head Bolts
      G04619111Courtesy of FORD MOTOR CO.
  45. Remove the cylinder head alignment dowels.
    Fig 44: Identifying Cylinder Head Alignment Dowels
    G03898024Courtesy of FORD MOTOR CO.
  46. Remove the bolts and the oil pan.
    Fig 45: Locating Bolts & Oil Pan
    G04619113Courtesy of FORD MOTOR CO.
  47. Remove the bolts and the rear crankshaft seal.
    Fig 46: Locating Rear Crankshaft Seal & Bolt
    G04619114Courtesy of FORD MOTOR CO.
  48. Remove the bolts, oil pump pickup tube and gasket.
    Fig 47: Locating Oil Pump Pickup Tube & Gasket
    G04619115Courtesy of FORD MOTOR CO.
  49. Remove the bolts and the oil pump.
    Fig 48: Locating Oil Pump Bolts
    G04619116Courtesy of FORD MOTOR CO.
  50. Remove the bolts and the block-off plate.
    Fig 49: Locating Block-Off Plate & Bolts
    G04619117Courtesy of FORD MOTOR CO.
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