LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1991 (Engine - 2.3L - (Hybrid)) >> Disassembly >> Engine

Section 1991 (Engine - 2.3L - (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 engine assembly.
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.

All vehicles 

  1. Remove the 6 bolts and the flywheel.
    2. Fig 1: Flywheel Bolts
    GF0024151Courtesy of FORD MOTOR CO.
  2. Mount the engine on a suitable stand.
  3. Disconnect the crankshaft position (CKP) sensor electrical connector.
    4. Fig 2: Crankshaft Position (CKP) Sensor Electrical Connector
    GF0024153Courtesy of FORD MOTOR CO.
  4. Remove the bolt and the engine wiring harness connector bracket.
    5. Fig 3: Engine Wiring Harness Connector Bracket & Bolt
    GF0024410Courtesy of FORD MOTOR CO.
  5. Detach the engine wiring harness pin-type retainer.
    6. Fig 4: Engine Wiring Harness Pin-Type Retainer
    GF0024411Courtesy of FORD MOTOR CO.
  6. Remove the 3 bolts and the accessory drive belt tensioner.
    7. Fig 5: Accessory Drive Belt Tensioner & Bolts
    GF0024412Courtesy of FORD MOTOR CO.
  7. Disconnect the coil-on-plug and camshaft position (CMP) sensor electrical connectors.
    8. Fig 6: Locating Camshaft Position Sensor Electrical Connectors And Coil-On-Plug
    GF0024182Courtesy of FORD MOTOR CO.
  8. Position the rubber boot aside and disconnect the cylinder head temperature (CHT) sensor electrical connector.
    9. Fig 7: Locating Cylinder Head Temperature Sensor Electrical Connector And Rubber Boot
    GF0024184Courtesy of FORD MOTOR CO.
  9. If equipped, disconnect the block heater electrical connector.
    10. Fig 8: Block Heater Electrical Connector
    GF0024121Courtesy of FORD MOTOR CO.
  10. Disconnect the radio ignition interference capacitor electrical connector.
    11. Fig 9: Radio Ignition Interference Capacitor Electrical Connector
    GF0024413Courtesy of FORD MOTOR CO.
  11. Disconnect the exhaust gas recirculation (EGR) valve electrical connector and remove the engine control wiring harness from the engine.
    12. Fig 10: Exhaust Gas Recirculation (EGR) Valve Electrical Connector
    GF0024414Courtesy of FORD MOTOR CO.
  12. Remove the 3 bolts and the coolant pump pulley.
    13. Fig 11: Locating Coolant Pump Pulley Bolts
    G03897969Courtesy of FORD MOTOR CO.
  13. Remove the 3 bolts and the coolant pump.
    14. Fig 12: Locating Coolant Pump Bolts
    G03897970Courtesy of FORD MOTOR CO.
  14. Disconnect the coolant hose.
    15. Fig 13: Coolant Hose
    GF0024415Courtesy of FORD MOTOR CO.
  15. Remove the 3 bolts and the thermostat housing.
    16. Fig 14: Thermostat Housing & Bolts
    GF0024416Courtesy of FORD MOTOR CO.
  16. Disconnect the coolant hose.
    17. Fig 15: Locating Coolant Bypass Hose
    GF0024185Courtesy of FORD MOTOR CO.
  17. Remove the bolt and the knock sensor (KS).
    18. Fig 16: Locating KS And Bolt
    GF0024188Courtesy of FORD MOTOR CO.
  18. Remove the 8 bolts and the crankcase vent oil separator.
    19. Fig 17: Locating Crankcase Vent Oil Separator And Bolts
    GF0024189Courtesy of FORD MOTOR CO.
  19. Remove the 4 bolts and the oil filter adapter. Discard the gasket.
    20. Fig 18: Oil Filter Adapter & Bolts
    GF0024417Courtesy of FORD MOTOR CO.
  20. Disconnect and remove the coolant hoses.
    21. Fig 19: Coolant Hoses
    GF0024418Courtesy of FORD MOTOR CO.
  21. If equipped, remove the block heater.
    22. Fig 20: Locating Block Heater
    GF0009034Courtesy of FORD MOTOR CO.
  22. Remove the engine cover studs.
    23. Fig 21: Engine Cover Studs
    GF0024419Courtesy of FORD MOTOR CO.
  23. Remove the crankcase vent tube and the coil-on-plugs.
    24. Fig 22: 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.
  24. Remove the spark plugs and the CHT sensor.
    • Discard the CHT sensor.
    25. Fig 23: Locating Cylinder Head Temperature Sensor And Spark Plugs
    GF0024191Courtesy of FORD MOTOR CO.
  25. Remove the bolts and the valve cover.
    26. Fig 24: 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.
  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.
    27. Fig 25: 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.
  27. Install the special tool in the slots on the rear of both camshafts.
    28. Fig 26: Identifying Special Camshaft Tool (303-465)
    G03898006Courtesy of FORD MOTOR CO.
  28. Remove the engine plug bolt.
    29. Fig 27: 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 the crankshaft pulley removal and installation.
  29. Install the special tool.
    30. Fig 28: Identifying Special Tool (303-507)
    G04617907Courtesy of FORD MOTOR CO.
    NOTE: 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).
    NOTE: The crankshaft sprocket diamond washer may come off with the crankshaft pulley. The diamond washer must be replaced; remove and discard the diamond washer. If the diamond washer is not installed, engine damage may occur.
    NOTE: Remove the diamond washer and discard.
  30. Using the special tool and an air impact wrench, remove the crankshaft pulley.

    Remove and discard the crankshaft pulley bolt and washer.

    Remove the crankshaft pulley.

    31. Fig 29: Locating Crankshaft Pulley Bolt
    G00553658Courtesy of FORD MOTOR CO.
    CAUTION: Use care not to damage the engine front cover or the crankshaft when removing the seal.
  31. Using the special tools and an air impact wrench, remove the crankshaft pulley.
    32. Fig 30: Identifying Special Tool (303--409) And Crankshaft Front Oil Seal
    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.
  32. Remove and discard the CKP sensor.
    33. Fig 31: Locating CKP Sensor
    G03898012Courtesy of FORD MOTOR CO.
  33. Remove the bolts and the engine front cover.
    34. Fig 32: Locating Engine Front Cover Bolts
    G03897743Courtesy of FORD MOTOR CO.
  34. Compress the timing chain tensioner in the following sequence.
    1. Using a small pick, release and hold the ratchet mechanism.
    2. While holding the ratchet mechanism in the released position, compress the tensioner by pushing the timing chain arm toward the tensioner.
    3. Insert a paper clip into the hole to retain the tensioner.
      4. Fig 33: Identifying Paper Clip Into Hole And Bolts
      G00553659Courtesy of FORD MOTOR CO.
  35. Remove the 2 bolts and the timing chain tensioner.
    Fig 34: Identifying Paper Clip Into Hole And Bolts
    G00553659Courtesy of FORD MOTOR CO.
  36. Remove the RH timing chain guide.
    37. Fig 35: Locating RH Timing Chain Guide
    G03897778Courtesy of FORD MOTOR CO.
  37. Remove the timing chain.
    38. Fig 36: View Of Timing Chain
    G03897779Courtesy of FORD MOTOR CO.
  38. Remove the bolts and the LH timing chain guide.
    39. Fig 37: 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.
  39. Using the flats on the camshaft to prevent camshaft rotation, remove the bolts and the camshaft sprockets.
    40. Fig 38: Locating Cam Holding Area And Sprocket Bolt
    G03897781Courtesy of FORD MOTOR CO.

    Early build vehicles 

  40. 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.
    41. Fig 39: Locating Oil Pump Bolts
    GF0024101Courtesy of FORD MOTOR CO.

    Late build vehicles 

  41. Remove the oil pump chain tensioner.
    • Release the tension on the tensioner spring.
    • Remove the tensioner and the 2 shoulder bolts.
    42. Fig 40: 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.
  42. Remove the oil pump chain and sprockets.
    1. Remove the bolt.
    2. Remove the chain and sprockets.
    43. Fig 41: Identifying Bolt, Chain And Sprockets
    GF0024194Courtesy of FORD MOTOR CO.
  43. Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.
    44. Fig 42: Locating Camshaft Lobe
    G03898791Courtesy of FORD MOTOR CO.
    CAUTION: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.
  44. 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.
    45. Fig 43: Identifying Loosening Sequence Of Camshaft Bearing Bolts
    G03897808Courtesy of FORD MOTOR CO.
  45. Remove the cylinder head.
    • Remove and discard the cylinder head bolts.
    • Remove the cylinder head.
    • Remove and discard the cylinder head gasket.
    46. Fig 44: Locating Cylinder Head Bolts
    GF0009061Courtesy of FORD MOTOR CO.
  46. Remove the cylinder head alignment dowels.
    47. Fig 45: Identifying Cylinder Head Alignment Dowels
    G03898024Courtesy of FORD MOTOR CO.
  47. Remove the bolts and the oil pan.
    48. Fig 46: Locating Oil Pan Bolts
    GF0009062Courtesy of FORD MOTOR CO.
  48. Remove the bolts and the rear crankshaft seal.
    49. Fig 47: Locating Rear Crankshaft Seal Bolts
    GF0009063Courtesy of FORD MOTOR CO.
  49. Remove the bolts, oil pump pickup tube and gasket.
    50. Fig 48: Locating Oil Pump Pickup Tube Bolts
    GF0024195Courtesy of FORD MOTOR CO.
  50. Remove the bolts and the oil pump.
    51. Fig 49: Locating Oil Pump Assembly & Bolts
    GF0009065Courtesy of FORD MOTOR CO.
  51. Remove the bolts and the block-off plate.
    Fig 50: Block-Off Plate & Bolts
    GF0024420Courtesy of FORD MOTOR CO.
  52. Make sure the Crankshaft TDC Timing Peg is still installed and the engine is still at TDC.

    Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg.

    Fig 51: Locating Crankshaft TDC Timing Peg
    G00553660Courtesy of FORD MOTOR CO.
  53. Mark the balancer unit front shafts on the top for reference that the balancer unit is at TDC.
    Fig 52: Marking Balancer Unit Front Shafts
    G00553661Courtesy of FORD MOTOR CO.
    54. NOTE: Due to the precision interior construction of the balancer unit, it should not be disassembled.
    Fig 53: Locating Balancer Unit Bolts
    G00553662Courtesy of FORD MOTOR CO.
  54. Remove the 4 bolts and the balancer unit.
  55. Remove the Crankshaft TDC Timing Peg.
    Fig 54: Locating Crankshaft TDC Timing Peg
    G00553663Courtesy of FORD MOTOR CO.
  56. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad or equivalent, following manufacturer's instructions.
    57. NOTE: Clearly mark the connecting rods, connecting rod caps and connecting rod bearings in numerical order for correct orientation for reassembly.
    Fig 55: Locating Connecting Rod Cap Bolts And Cap
    G00553664Courtesy of FORD MOTOR CO.
  57. Remove the connecting rod cap bolts and cap
    58. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
  58. Using the Connecting Rod Installer, remove the piston/rod assembly from the engine block.

    Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine block.

  59. Remove the bolts in the sequence shown.

    Remove the main bearing beam.

    Discard the bolts.

    Fig 56: Main Bearing Beam Bolts Removal Sequence
    G00553665Courtesy of FORD MOTOR CO.
  60. Remove the crankshaft from the engine block.
    Fig 57: Locating Crankshaft
    G00553666Courtesy of FORD MOTOR CO.
    61. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.
    Fig 58: Locating Main Bearings On Main Bearing Beam
    G00553667Courtesy of FORD MOTOR CO.
  61. Remove the main bearings from the main bearing beam.
    62. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.
    NOTE: The center bulkhead has the thrust bearing.
    Fig 59: Locating Main Bearings On Cylinder Block
    G00553668Courtesy of FORD MOTOR CO.
  62. Remove the main bearings from the cylinder block.
    63. NOTE: If the oil squirters are being reused, mark them in order for correct location during reassembly.
    NOTE: The front bulkhead does not have an oil squirter.
    Fig 60: Locating Oil Squirters
    G00553669Courtesy of FORD MOTOR CO.
  63. Remove the 4 oil squirters
  64. Inspect the cylinder block, main bearing beam, pistons and connecting rods. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION
scientia non olet · About LEMON Manuals