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Section 1989 (Engine - 2.3L - (Except Hybrid)): Disassembly: Engine

WARNING: This page is about a different car, the 2007 Mercury Mariner and 2007 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
Special Tools

Illustration Tool Name Tool Number
GF0000536
 Heavy Duty Floor Crane 014-00071 or equivalent
GF0000267
 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
GF0009023
 Engine Stand 014-00232 or equivalent
GF0008917
 Alignment Plate, Camshaft 303-465 (T94P-6256-CH)
GF0008919
 Timing Peg, Crankshaft 303-507
GF0008918
 Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A)
GF0008916
 Adapter for 205-126 (205-072-02)
GF0000249
 Remover, Oil Seal 303-409 (T92C-6700-CH)
CAUTION: 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.
CAUTION: 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.
CAUTION: 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 the engine assembly procedure.
NOTE: Early build engines are equipped with an oil pump drive chain guide. Late build engines do not have an oil pump drive chain guide. Also, late build engines use an updated design for the oil pump drive chain and tensioner. Therefore, the oil pump drive components are not interchangeable between early build and late build engines.

Vehicles with manual transaxle 

    WARNING: The clutch disc and clutch pressure plate are heavy and may fall if not held when the bolts are removed. Failure to follow these instructions may result in personal injury.
    CAUTION: Loosen the bolts evenly to prevent pressure plate damage.
  1. Remove the bolts, clutch pressure plate and clutch disc.
    2. Fig 1: Locating Clutch Pressure Plate Bolts
    GF0024149Courtesy of FORD MOTOR CO.
  2. Remove the starter motor isolator.
    3. Fig 2: Locating Starter Motor Isolator
    GF0024150Courtesy of FORD MOTOR CO.
  3. Remove the bolts and the flywheel.
    4. Fig 3: Flywheel Bolts
    GF0024151Courtesy of FORD MOTOR CO.

    Vehicles with automatic transaxle 

  4. Remove the bolts and the flexplate.
    5. Fig 4: Locating Flexplate Bolts
    GF0024152Courtesy of FORD MOTOR CO.

    All vehicles 

  5. Mount the engine on a suitable stand.
  6. Disconnect the crankshaft position (CKP) sensor electrical connector.
    7. Fig 5: Crankshaft Position (CKP) Sensor Electrical Connector
    GF0024153Courtesy of FORD MOTOR CO.
  7. Remove the nut and disconnect the generator electrical connections.
    8. Fig 6: Locating Generator Electrical Connections
    GF0024154Courtesy of FORD MOTOR CO.
  8. Remove the 2 lower catalytic converter bolts.
    9. Fig 7: Locating Lower Catalytic Converter Bolts
    GF0024155Courtesy of FORD MOTOR CO.
  9. Remove the 6 heat shield bolts and the heat shield.
    10. Fig 8: Locating Heat Shield & Bolts
    GF0024156Courtesy of FORD MOTOR CO.
  10. Remove and discard the 7 exhaust manifold nuts.
    11. Fig 9: Locating Exhaust Manifold Nuts
    GF0024157Courtesy of FORD MOTOR CO.
  11. Remove the catalytic converter and discard the exhaust manifold gasket.
  12. Remove the bolts and the generator.
    13. Fig 10: Locating Generator & Bolts
    GF0024158Courtesy of FORD MOTOR CO.
  13. Loosen the bolt and remove the accessory drive belt idler pulley.
    14. Fig 11: Locating Accessory Drive Belt Idler Pulley Bolt
    GF0024159Courtesy of FORD MOTOR CO.
  14. If equipped, loosen the bolt and remove the accessory drive belt idler pulley.
    15. Fig 12: Locating Accessory Drive Belt Idler Pulley And Bolt
    GF0024160Courtesy of FORD MOTOR CO.
  15. Remove the bolts and the coolant pump pulley.
    16. Fig 13: Locating Coolant Pump Pulley Bolts
    G03897969Courtesy of FORD MOTOR CO.
  16. Remove the bolts and the coolant pump.
    17. Fig 14: Locating Coolant Pump Bolts
    G03897970Courtesy of FORD MOTOR CO.
  17. Remove the engine vacuum tube.
    • Detach the 2 engine vacuum tube retainers.
    • Disconnect and remove the engine vacuum tube.
    18. Fig 15: Locating Engine Vacuum Tube
    GF0024161Courtesy of FORD MOTOR CO.
  18. Detach the 2 wiring harness retainers and position the harness aside.
    19. Fig 16: Locating Wiring Harness Retainers
    GF0024162Courtesy of FORD MOTOR CO.
  19. Remove the bolts and the thermostat housing assembly.
    20. Fig 17: Locating Thermostat Housing & Bolts
    GF0024163Courtesy of FORD MOTOR CO.
  20. Remove the bolts and the oil level indicator.
    21. Fig 18: Locating Oil Level Indicator & Bolts
    GF0024164Courtesy of FORD MOTOR CO.
  21. Disconnect the oil pressure sensor electrical connector.
    22. Fig 19: Locating Engine Oil Pressure (EOP) Sensor Electrical Connector
    GF0009004Courtesy of FORD MOTOR CO.
  22. Remove the engine oil filter.
    23. Fig 20: Locating Engine Oil Filter
    GF0024165Courtesy of FORD MOTOR CO.
  23. Remove the 4 bolts and the oil filter adapter.
    • Discard the gasket.
    24. Fig 21: Locating Oil Filter Adapter And Bolts
    GF0024166Courtesy of FORD MOTOR CO.
    CAUTION: A new oil cooler must be installed or severe damage to the engine can occur.
  24. Position the oil filter adapter in a vise and remove the oil cooler bolt and oil cooler.
    • Discard the oil cooler.
  25. If equipped, remove the bolt and capacitor.
    26. Fig 22: Locating Capacitor & Bolt
    GF0024167Courtesy of FORD MOTOR CO.
  26. Detach the 2 wiring harness retainers.
    27. Fig 23: Locating Wiring Harness Retainers
    GF0024168Courtesy of FORD MOTOR CO.
  27. Disconnect the knock sensor (KS) and detach the 2 wiring harness retainers.
    28. Fig 24: Locating Knock Sensor (KS) & Wiring Harness Retainers
    GF0024169Courtesy of FORD MOTOR CO.
  28. Disconnect the temperature manifold absolute pressure (TMAP) electrical connector.
    29. Fig 25: Locating Temperature Manifold Absolute Pressure (TMAP) Electrical Connector
    GF0024170Courtesy of FORD MOTOR CO.
  29. Disconnect the idle air control (IAC) motor electrical connector.
    30. Fig 26: Locating Idle Air Control (IAC) Motor Electrical Connector
    GF0024171Courtesy of FORD MOTOR CO.
  30. Disconnect the swirl control valve electrical connector.
    31. Fig 27: Locating Swirl Control Valve Electrical Connector
    GF0024172Courtesy of FORD MOTOR CO.
  31. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum tube.
    32. Fig 28: Locating Fuel Rail Pressure & Temperature Sensor Electrical Connector
    GF0024173Courtesy of FORD MOTOR CO.
  32. Disconnect the throttle position (TP) sensor electrical connector.
    33. Fig 29: Locating Throttle Position (TP) Sensor Electrical Connector
    GF0024174Courtesy of FORD MOTOR CO.
    NOTE: There are 3 different size bolts used. Mark the location of the bolts to make sure of installation in the correct locations.
  33. Remove the bolts and position the intake manifold aside.
    34. Fig 30: Locating Intake Manifold Gaskets & Intake Manifold
    GF0024175Courtesy of FORD MOTOR CO.
  34. Disconnect the positive crankcase ventilation (PCV) hose and remove the intake manifold.
    35. Fig 31: Locating Positive Crankcase Ventilation Hose
    GF0024176Courtesy of FORD MOTOR CO.
  35. Remove the exhaust gas recirculation (EGR) tube.
    36. Fig 32: Locating Exhaust Gas Recirculation (EGR) Tube
    GF0024177Courtesy of FORD MOTOR CO.
  36. Disconnect the 4 fuel injector electrical connectors. Detach the 2 wiring harness retainers.
    37. Fig 33: Locating Fuel Injector Electrical Connectors
    GF0024178Courtesy of FORD MOTOR CO.
  37. Remove the 2 bolts and the fuel rail with the fuel injectors.
    38. Fig 34: Locating Fuel Rail With Fuel Injectors & Bolts
    GF0024179Courtesy of FORD MOTOR CO.
  38. Detach the wiring harness retainer.
    39. Fig 35: Locating Wiring Harness Retainer
    GF0024180Courtesy of FORD MOTOR CO.
  39. Disconnect the EGR valve and radio interference capacitor electrical connectors. Detach the wiring harness retainer.
    40. Fig 36: Locating EGR Valve & Radio Interference Capacitor Electrical Connectors
    GF0024181Courtesy of FORD MOTOR CO.
  40. Disconnect the coil-on-plug and camshaft position (CMP) sensor electrical connectors.
    41. Fig 37: Locating Camshaft Position Sensor Electrical Connectors And Coil-On-Plug
    GF0024182Courtesy of FORD MOTOR CO.
  41. Detach the wiring harness retainer.
    42. Fig 38: Locating Wiring Harness Retainer
    GF0024183Courtesy of FORD MOTOR CO.
  42. Position the rubber boot aside and disconnect the cylinder head temperature (CHT) sensor electrical connector. Remove the wiring harness from the engine.
    43. Fig 39: Locating Cylinder Head Temperature Sensor Electrical Connector And Rubber Boot
    GF0024184Courtesy of FORD MOTOR CO.
  43. Disconnect the coolant hose.
    44. Fig 40: Locating Coolant Bypass Hose
    GF0024185Courtesy of FORD MOTOR CO.
  44. Disconnect and remove the coolant hose.
    45. Fig 41: Locating Coolant Hose
    GF0024186Courtesy of FORD MOTOR CO.
  45. Disconnect and remove the coolant hoses.
    46. Fig 42: Locating Coolant Hose
    GF0024187Courtesy of FORD MOTOR CO.
  46. Remove the bolt and the KS.
    47. Fig 43: Locating Knock Sensor Bolt
    GF0024188Courtesy of FORD MOTOR CO.
  47. Remove the bolts and the crankcase vent oil separator.
    48. Fig 44: Locating Crankcase Vent Oil Separator And Bolts
    GF0024189Courtesy of FORD MOTOR CO.
  48. If equipped, remove the block heater.
    49. Fig 45: Locating Block Heater
    GF0009034Courtesy of FORD MOTOR CO.
  49. Remove the crankcase vent tube and the coil-on-plugs.
    50. Fig 46: Locating Crankcase Vent Tube And Coil-On-Plugs
    GF0024190Courtesy of FORD MOTOR CO.
    CAUTION: Only use hand tools when removing or installing the spark plugs, damage can occur to the cylinder head or spark plug.
  50. Remove the spark plugs and the CHT sensor.
    • Discard the CHT.
    51. Fig 47: Locating Cylinder Head Temperature (CHT) Sensor & Spark Plugs
    GF0024191Courtesy of FORD MOTOR CO.
  51. Remove the bolts and the valve cover.
    52. Fig 48: Locating Valve Cover Bolts
    GF0024192Courtesy of FORD MOTOR CO.
    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.
  52. 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.
    53. Fig 49: Turning Crankshaft Clockwise
    GF0024070Courtesy of FORD MOTOR CO.
    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.
  53. Install the special tool in the slots on the rear of both camshafts.
    54. Fig 50: Identifying Special Camshaft Tool (303-465)
    G03898006Courtesy of FORD MOTOR CO.
  54. Remove the engine plug bolt.
    55. Fig 51: Locating Engine Plug Bolt
    G04319319Courtesy of FORD MOTOR CO.
    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 disassembly.
  55. Install the special tool.
    56. Fig 52: Identifying Special Tool (303-507)
    G04617907Courtesy of FORD MOTOR CO.
  56. Assemble the special tools using 4 hardened washers in the locations shown.
    57. Fig 53: Assembling Special Tools (205-126 And 205-072-02) And Hardened Washers
    GF0024071Courtesy of FORD MOTOR CO.
    CAUTION: 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).
    CAUTION: If the crankshaft sprocket diamond washer comes off with the crankshaft pulley, it must be installed back onto the crankshaft.
  57. 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.
    58. Fig 54: Using Special Tools (205-126 And 205-072-02)
    GF0024072Courtesy of FORD MOTOR CO.
    CAUTION: Use care not to damage the engine front cover or the crankshaft when removing the seal.
  58. Using the special tool, remove the crankshaft front oil seal.
    59. Fig 55: Removing Crankshaft Front Oil Seal Using Special Tool (303-409)
    GF0024193Courtesy of FORD MOTOR CO.
    NOTE: Whenever the CKP sensor is removed, a new one must be installed using the alignment tool supplied with the new part.
  59. Remove and discard the CKP sensor.
    60. Fig 56: Locating CKP Sensor
    G03898012Courtesy of FORD MOTOR CO.
  60. Remove the bolts and the engine front cover.
    61. Fig 57: Locating Engine Front Cover Bolts
    G03897743Courtesy of FORD MOTOR CO.
  61. 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.
    62. Fig 58: Identifying Paper Clip Into Hole And Bolts
    GF0024079Courtesy of FORD MOTOR CO.
  62. Remove the RH timing chain guide.
    63. Fig 59: Locating RH Timing Chain Guide
    G03897778Courtesy of FORD MOTOR CO.
  63. Remove the timing chain.
    64. Fig 60: View Of Timing Chain
    G03897779Courtesy of FORD MOTOR CO.
  64. Remove the bolts and the LH timing chain guide.
    65. Fig 61: Identifying Bolts And LH Timing Chain Guide
    G03897780Courtesy of FORD MOTOR CO.
    CAUTION: Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation. Damage to the tool or the camshaft can occur.
  65. Using the flats on the camshaft to prevent camshaft rotation, remove the bolts and the camshaft sprockets.
    66. Fig 62: Locating Cam Holding Area And Sprocket Bolt
    G03897781Courtesy of FORD MOTOR CO.

    Early build vehicles 

  66. Remove the oil pump drive chain tensioner and guide.
    1. Release the tension on the tensioner spring.
    2. Remove the tensioner and the shoulder bolt.
    3. Remove the guide.
    67. Fig 63: Locating Tensioner Shoulder Bolts, Tensioner Spring And Guide
    GF0024101Courtesy of FORD MOTOR CO.

    Late build vehicles 

  67. Remove the oil pump drive chain tensioner.
    • Release the tension on the tensioner spring.
    • Remove the tensioner and the 2 shoulder bolts.
    68. Fig 64: Locating Shoulder Bolts & Tensioner
    GF0009058Courtesy of FORD MOTOR CO.

    All vehicles 

    NOTE: Remove the crankshaft sprocket diamond washers located in front of and behind the crankshaft sprocket.
    NOTE: The oil pump chain sprocket must be held in place.
  68. Remove the oil pump chain and sprockets.
    1. Remove the bolt.
    2. Remove the chain and sprockets.
    69. Fig 65: Identifying Bolt, Chain And Sprockets
    GF0024194Courtesy of FORD MOTOR CO.
  69. Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.
    70. Fig 66: Locating Camshaft Lobe
    G03898791Courtesy of FORD MOTOR CO.
    CAUTION: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.
  70. Remove the camshafts from the engine.
    • Loosen the camshaft bearing bolts in the sequence shown, one turn at a time. Repeat until all the tension is released.
    • Remove the camshaft bearing caps.
    • Remove the camshafts.
    71. Fig 67: Identifying Loosening/Tightening Sequence Of Camshaft Bearing Bolts
    G03897808Courtesy of FORD MOTOR CO.
  71. Remove the cylinder head.
    • Remove and discard the cylinder head bolts.
    • Remove the cylinder head.
    • Remove and discard the cylinder head gasket.
    72. Fig 68: Locating Cylinder Head Bolts
    GF0009061Courtesy of FORD MOTOR CO.
  72. Remove the cylinder head alignment dowels.
    73. Fig 69: Identifying Cylinder Head Alignment Dowels
    G03898024Courtesy of FORD MOTOR CO.
  73. Remove the bolts and the oil pan.
    74. Fig 70: Locating Oil Pan Bolts
    GF0009062Courtesy of FORD MOTOR CO.
  74. Remove the bolts and the rear crankshaft seal.
    75. Fig 71: Locating Rear Crankshaft Seal Bolts
    GF0009063Courtesy of FORD MOTOR CO.
  75. Remove the bolts, oil pump pickup tube and gasket.
    76. Fig 72: Locating Oil Pump Pickup Tube Bolts
    GF0024195Courtesy of FORD MOTOR CO.
  76. Remove the bolts and the oil pump.
    77. Fig 73: Locating Oil Pump Assembly & Bolts
    GF0009065Courtesy of FORD MOTOR CO.
  77. If necessary, remove the bolts and halfshaft support bracket.
    78. Fig 74: Locating Halfshaft Support Bracket & Bolts
    GF0024196Courtesy of FORD MOTOR CO.
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