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Section 2152 (Engine - 2.3L - (Except Hybrid)): Disassembly: Engine

WARNING: This page is about a different car, the 2008 Mercury Mariner and 2008 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
Special Tools

Illustration Tool Name Tool Number
GF0008916Courtesy of FORD MOTOR CO.
 Adapter for 205-126 (205-072-02)
GF0008917Courtesy of FORD MOTOR CO.
 Alignment Plate, Camshaft 303-465 (T94P-6256-CH)
GF0009023Courtesy of FORD MOTOR CO.
 Engine Stand 014-00232 or equivalent
GF0000536Courtesy of FORD MOTOR CO.
 Heavy Duty Floor Crane 014-00071 or equivalent
GF0008918Courtesy of FORD MOTOR CO.
 Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A)
GF0000249Courtesy of FORD MOTOR CO.
 Remover, Oil Seal 303-409 (T92C-6700-CH)
GF0000267Courtesy of FORD MOTOR CO.
 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
GF0008919Courtesy of FORD MOTOR CO.
 Timing Peg, Crankshaft 303-507
NOTE: 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.
NOTE: 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.
NOTE: 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 in this article.

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 this instruction may result in serious personal injury.
    NOTE: 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.

    Front wheel drive (FWD) vehicles 

  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 and discard the 7 exhaust manifold studs.

    13. All vehicles 

  13. Remove the nut, bolts and the generator.
    14. Fig 10: Locating Generator & Bolts
    GF0024158Courtesy of FORD MOTOR CO.
  14. Loosen the bolt and remove the accessory drive belt idler pulley.
    15. Fig 11: Locating Accessory Drivebelt Idler Pulley And Bolt
    GF0024159Courtesy of FORD MOTOR CO.
  15. Remove the 3 bolts and the accessory drive belt idler pulley and bracket.
    16. Fig 12: Identifying Bolts
    GF0042025Courtesy of FORD MOTOR CO.
  16. Remove the bolts and the coolant pump pulley.
    17. Fig 13: Locating Coolant Pump Pulley Bolts
    G03897969Courtesy of FORD MOTOR CO.
  17. Remove the bolts and the coolant pump.
    18. Fig 14: Locating Coolant Pump Bolts
    G03897970Courtesy of FORD MOTOR CO.
  18. Detach the 2 wiring harness retainers.
    19. Fig 15: Locating Wiring Harness Retainers
    GF0024162Courtesy of FORD MOTOR CO.
  19. Remove the 3 bolts and the thermostat housing assembly.
    20. Fig 16: Locating Thermostat Housing & Bolts
    GF0024163Courtesy of FORD MOTOR CO.
  20. Remove the bolt and the oil level indicator.
    21. Fig 17: Identifying Bolt And Oil Level indicator
    GF0042057Courtesy of FORD MOTOR CO.
  21. Disconnect the engine oil pressure (EOP) switch electrical connector.
    22. Fig 18: Locating Engine Oil Pressure (EOP) Sensor Electrical Connector
    GF0009004Courtesy of FORD MOTOR CO.
  22. Remove the engine oil filter.
    23. Fig 19: Locating Engine Oil Filter
    GF0024165Courtesy of FORD MOTOR CO.
  23. Remove the 4 bolts and the oil filter adapter.
    • Discard the gasket.
    24. Fig 20: Locating Oil Filter Adapter And Bolts
    GF0024166Courtesy of FORD MOTOR CO.
  24. If equipped, remove the bolt and capacitor.
    25. Fig 21: Locating Capacitor & Bolt
    GF0024167Courtesy of FORD MOTOR CO.
  25. Detach the 2 wiring harness retainers.
    26. Fig 22: Locating Wiring Harness Retainers
    GF0024168Courtesy of FORD MOTOR CO.
  26. Disconnect the knock sensor (KS) and detach the 2 wiring harness retainers.
    27. Fig 23: Locating Knock Sensor (KS) & Wiring Harness Retainers
    GF0024169Courtesy of FORD MOTOR CO.
  27. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
    28. Fig 24: Locating Manifold Actual Pressure (MAP) Sensor Electrical Connector
    GF0024170Courtesy of FORD MOTOR CO.
  28. Disconnect the idle air control (IAC) motor electrical connector.
    29. Fig 25: Locating Idle Air Control (IAC) Motor Electrical Connector
    GF0024171Courtesy of FORD MOTOR CO.
  29. Disconnect the swirl control valve electrical connector.
    30. Fig 26: Locating Swirl Control Valve Electrical Connector
    GF0024172Courtesy of FORD MOTOR CO.
  30. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum tube.
    31. Fig 27: Locating Fuel Rail Pressure & Temperature Sensor Electrical Connector
    GF0024173Courtesy of FORD MOTOR CO.
  31. Disconnect the radio capacitor electrical connector.
    32. Fig 28: Identifying Connector
    GF0042058Courtesy 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 2 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 (PCV) Hose
    GF0024176Courtesy of FORD MOTOR CO.
  35. Remove the 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: Identifying Connectors And Retainers
    GF0042059Courtesy of FORD MOTOR CO.
  37. Remove the nut and the radio capacitor.
    38. Fig 34: Identifying Nut And Radio Capacitor
    GF0042060Courtesy of FORD MOTOR CO.
  38. Remove the 2 stud bolts and the fuel rail with the fuel injectors.
    39. Fig 35: Identifying Bolts And Fuel Rail
    GF0042061Courtesy of FORD MOTOR CO.
  39. Detach the wiring harness retainer.
    40. Fig 36: Locating Wiring Harness Retainer
    GF0024180Courtesy of FORD MOTOR CO.
  40. Disconnect the EGR valve electrical connectors.
    • Detach the wiring harness retainer.
    41. Fig 37: Identifying Connector And Retainer
    GF0042062Courtesy of FORD MOTOR CO.
  41. Disconnect the coil-on-plug and camshaft position (CMP) sensor electrical connectors.
    42. Fig 38: Locating Camshaft Position Sensor Electrical Connectors And Coil-On-Plug
    GF0024182Courtesy of FORD MOTOR CO.
  42. Detach the wiring harness retainer.
    43. Fig 39: Locating Wiring Harness Retainer
    GF0024183Courtesy of FORD MOTOR CO.
  43. Position the rubber boot aside and disconnect the cylinder head temperature (CHT) sensor electrical connector.
    • Remove the wiring harness from the engine.
    44. Fig 40: Locating Cylinder Head Temperature Sensor Electrical Connector And Rubber Boot
    GF0024184Courtesy of FORD MOTOR CO.
  44. Disconnect the coolant hose.
    45. Fig 41: Locating Coolant Bypass Hose
    GF0024185Courtesy of FORD MOTOR CO.
  45. Disconnect and remove the coolant hose.
    46. Fig 42: Locating Coolant Hose
    GF0024186Courtesy of FORD MOTOR CO.
  46. Disconnect and remove the coolant hoses.
    47. Fig 43: Locating Coolant Hoses
    GF0024187Courtesy of FORD MOTOR CO.
  47. Remove the bolt and the KS.
    48. Fig 44: Locating Knock Sensor Bolt
    GF0024188Courtesy of FORD MOTOR CO.
  48. Remove the bolts and the crankcase vent oil separator.
    49. Fig 45: Locating Crankcase Vent Oil Separator And Bolts
    GF0024189Courtesy of FORD MOTOR CO.
  49. If equipped, remove the block heater.
    50. Fig 46: Locating Block Heater
    GF0009034Courtesy of FORD MOTOR CO.
  50. Remove the crankcase vent tube and the coil-on-plugs.
    51. Fig 47: Locating Crankcase Vent Tube And Coil-On-Plugs
    GF0024190Courtesy of FORD MOTOR CO.
    NOTE: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug.
  51. Remove the spark plugs and the CHT sensor.
    • Discard the CHT.
    52. Fig 48: Locating Cylinder Head Temperature (CHT) Sensor & Spark Plugs
    GF0024191Courtesy of FORD MOTOR CO.
  52. Remove the bolts and the valve cover.
    53. Fig 49: Locating Valve Cover Bolts
    GF0024192Courtesy of FORD MOTOR CO.
    NOTE: 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.
  53. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at top dead center (TDC).
    • The hole in the crankshaft pulley should be in the 6 o'clock position.
    54. Fig 50: Turning Crankshaft Clockwise
    GF0024070Courtesy of FORD MOTOR CO.
    NOTE: 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.
  54. Install the special tool in the slots on the rear of both camshafts.
    55. Fig 51: Identifying Special Camshaft Tool (303-465)
    G03898006Courtesy of FORD MOTOR CO.
  55. Remove the engine plug bolt.
    56. Fig 52: 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 top dead center (TDC) position during disassembly.
  56. Install the special tool.
    57. Fig 53: Identifying Special Tool (303-507)
    G04617907Courtesy of FORD MOTOR CO.
  57. Assemble the special tools using 4 hardened washers in the locations shown.
    58. Fig 54: Assembling Special Tools (205-126 And 205-072-02) And Hardened Washers
    GF0024071Courtesy of FORD MOTOR CO.
    NOTE: The crankshaft must remain in the top dead center (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.
  58. 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.
    • Remove the diamond washer and discard.
    59. Fig 55: Using Special Tools (205-126 And 205-072-02)
    GF0024072Courtesy of FORD MOTOR CO.
    NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal.
  59. Using the special tool, remove the crankshaft front oil seal.
    60. Fig 56: Identifying Special Tool (303-409) And Crankshaft Front Oil Seal
    GF0024193Courtesy of FORD MOTOR CO.
    NOTE: Whenever the crankshaft position (CKP) sensor is removed, a new one must be installed using the alignment tool supplied with the new part.
  60. Remove and discard the CKP sensor.
    61. Fig 57: Locating CKP Sensor
    G03898012Courtesy of FORD MOTOR CO.
  61. Remove the bolts and the engine front cover.
    62. Fig 58: Locating Engine Front Cover Bolts
    G03897743Courtesy of FORD MOTOR CO.
  62. 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.
    63. Fig 59: Locating Timing Chain Tensioner Bolt
    GF0024079Courtesy of FORD MOTOR CO.
  63. Remove the RH timing chain guide.
    64. Fig 60: Locating RH Timing Chain Guide
    G03897778Courtesy of FORD MOTOR CO.
  64. Remove the timing chain.
    65. Fig 61: View Of Timing Chain
    G03897779Courtesy of FORD MOTOR CO.
  65. Remove the bolts and the LH timing chain guide.
    66. Fig 62: Identifying Bolts And LH Timing Chain Guide
    G03897780Courtesy of FORD MOTOR CO.
    NOTE: Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation. Damage to the tool or the camshaft can occur.
  66. Using the flats on the camshaft to prevent camshaft rotation, remove the bolts and the camshaft sprockets.
    67. Fig 63: Locating Cam Holding Area And Sprocket Bolt
    G03897781Courtesy of FORD MOTOR CO.
  67. Remove the oil pump drive chain tensioner.
    1. Release the tension on the tensioner spring.
    2. Remove the tensioner and the 2 shoulder bolts.
    68. Fig 64: Locating Shoulder Bolts & Tensioner
    GF0009058Courtesy of FORD MOTOR CO.
    NOTE: Remove and discard the crankshaft sprocket diamond washer located 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 Chain & 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.
    NOTE: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.
    NOTE: Mark the location and orientation of each camshaft bearing cap.
  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.
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