Section 2154 (Engine - 2.3L - (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
Courtesy of FORD MOTOR CO.	Adapter for 205-126	(205-072-02)
Courtesy of FORD MOTOR CO.	Alignment Plate, Camshaft	303-465 (T94P-6256-CH)
Courtesy of FORD MOTOR CO.	Engine Stand	014-00232 or equivalent
Courtesy of FORD MOTOR CO.	Heavy Duty Floor Crane	014-00071 or equivalent
Courtesy of FORD MOTOR CO.	Holding Fixture, Drive Pinion Flange	205-126 (T78P-4851-A)
Courtesy of FORD MOTOR CO.	Remover, Oil Seal	303-409 (T92C-6700-CH)
Courtesy of FORD MOTOR CO.	Spreader Bar	303-D089 (D93P-6001-A3) or equivalent
Courtesy 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 may 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 engine assembly in this article.

Remove the 6 bolts and the flywheel.

Fig 1: Flywheel Bolts

Courtesy of FORD MOTOR CO.

Mount the engine on a suitable stand.
Disconnect the crankshaft position (CKP) sensor electrical connector.

Fig 2: Crankshaft Position (CKP) Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

Remove the bolt and the engine wiring harness connector bracket.

Fig 3: Engine Wiring Harness Connector Bracket & Bolt

Courtesy of FORD MOTOR CO.

Detach the engine wiring harness pin-type retainer.

Fig 4: Engine Wiring Harness Pin-Type Retainer

Courtesy of FORD MOTOR CO.

Remove the 3 bolts and the accessory drive belt tensioner.

Fig 5: Accessory Drive Belt Tensioner & Bolts

Courtesy of FORD MOTOR CO.

Remove the 2 bolts and the oil level indicator tube.

Fig 6: Identifying Bolts

Courtesy of FORD MOTOR CO.

Disconnect the throttle body electrical connector.

Fig 7: Identifying Connector

Courtesy of FORD MOTOR CO.

Disconnect the upper coolant hose from the throttle body.

Fig 8: Identifying Coolant Hose

Courtesy of FORD MOTOR CO.

Disconnect the lower coolant hose from the throttle body.

Fig 9: Identifying Lower Coolant Hose

Courtesy of FORD MOTOR CO.

Disconnect the evaporative emissions (EVAP) tube quick connect coupling from the intake manifold. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.

Fig 10: Identifying EVAP Tube

Courtesy of FORD MOTOR CO.

Disconnect the engine oil pressure (EOP) switch electrical connector.

Fig 11: Identifying (EOP) Connector

Courtesy of FORD MOTOR CO.

Disconnect the manifold absolute pressure (MAP) sensor electrical connector.

Fig 12: Identifying (MAP) Connector

Courtesy of FORD MOTOR CO.

Disconnect the knock sensor (KS) electrical connector and detach the electrical connector pin-type retainer from the intake manifold.

Fig 13: Identifying (KS) Connector

Courtesy of FORD MOTOR CO.

Disconnect the 4 fuel injector electrical connectors and the radio capacitor electrical connector.

Fig 14: Identifying Connectors

Courtesy of FORD MOTOR CO.

Detach all the wire harness pin-type retainers from the intake manifold.
Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum tube.

Fig 15: Locating Fuel Rail Pressure & Temperature Sensor Electrical Connector

Courtesy 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.

Remove the 8 bolts and position the intake manifold aside.

Fig 16: Locating Intake Manifold Gaskets & Intake Manifold

Courtesy of FORD MOTOR CO.

Disconnect the PCV hose and remove the intake manifold.

Fig 17: Locating Positive Crankcase Ventilation (PCV) Hose

Courtesy of FORD MOTOR CO.

Remove the EGR tube.

Fig 18: Locating Exhaust Gas Recirculation (EGR) Tube

Courtesy of FORD MOTOR CO.

Remove the nut and the radio capacitor.

Fig 19: Identifying Nut And Radio Capacitor

Courtesy of FORD MOTOR CO.

Remove the 2 stud bolts and the fuel rail with the fuel injectors.

Fig 20: Identifying Bolts And Fuel Rail

Courtesy of FORD MOTOR CO.

Disconnect the coil-on-plug and camshaft position (CMP) sensor electrical connectors.

Fig 21: Locating Camshaft Position Sensor Electrical Connectors And Coil-On-Plug

Courtesy of FORD MOTOR CO.

Position the rubber boot aside and disconnect the cylinder head temperature (CHT) sensor electrical connector.

Fig 22: Locating Cylinder Head Temperature Sensor Electrical Connector And Rubber Boot

Courtesy of FORD MOTOR CO.

Disconnect the EGR valve electrical connector.
- Remove the engine control wiring harness from the engine.

Fig 23: Exhaust Gas Recirculation (EGR) Valve Electrical Connector

Courtesy of FORD MOTOR CO.

Remove the 3 bolts and the coolant pump pulley.

Fig 24: Locating Coolant Pump Pulley Bolts

Courtesy of FORD MOTOR CO.

Remove the 3 bolts and the coolant pump.

Fig 25: Locating Coolant Pump Bolts

Courtesy of FORD MOTOR CO.

Disconnect the coolant hose.

Fig 26: Coolant Hose

Courtesy of FORD MOTOR CO.

Remove the 3 bolts and the thermostat housing.

Fig 27: Thermostat Housing & Bolts

Courtesy of FORD MOTOR CO.

Disconnect the coolant hose.

Fig 28: Locating Coolant Bypass Hose

Courtesy of FORD MOTOR CO.

Remove the bolt and the knock sensor (KS).

Fig 29: Locating Knock Sensor Bolt

Courtesy of FORD MOTOR CO.

Remove the 8 bolts and the crankcase vent oil separator.

Fig 30: Locating Crankcase Vent Oil Separator And Bolts

Courtesy of FORD MOTOR CO.

Remove the 4 bolts and the oil filter adapter.
- Discard the gasket.

Fig 31: Oil Filter Adapter & Bolts

Courtesy of FORD MOTOR CO.

Disconnect and remove the coolant hoses.

Fig 32: Coolant Hoses

Courtesy of FORD MOTOR CO.

If equipped, remove the block heater.

Fig 33: Locating Block Heater

Courtesy of FORD MOTOR CO.

Remove the engine cover studs.

Fig 34: Engine Cover Studs

Courtesy of FORD MOTOR CO.

Remove the crankcase vent tube and the coil-on-plugs.

Fig 35: Locating Crankcase Vent Tube And Coil-On-Plugs

Courtesy 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.

Remove the spark plugs and the CHT sensor.
- Discard the CHT sensor.

Fig 36: Locating Cylinder Head Temperature (CHT) Sensor & Spark Plugs

Courtesy of FORD MOTOR CO.

Remove the bolts and the valve cover.

Fig 37: Locating Valve Cover Bolts

Courtesy 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.

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.

Fig 38: Turning Crankshaft Clockwise

Courtesy 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.

Install the special tool in the slots on the rear of both camshafts.

Fig 39: Identifying Special Camshaft Tool (303-465)

Courtesy of FORD MOTOR CO.

Remove the engine plug bolt.

Fig 40: Locating Engine Plug Bolt

Courtesy 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.

Install the special tool.

Fig 41: Identifying Special Tool (303-507)

Courtesy of FORD MOTOR CO.

Assemble the special tools using 4 hardened washers in the locations shown.

Fig 42: Assembling Special Tools (205-126 And 205-072-02) And Hardened Washers

Courtesy 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.

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.

Fig 43: Using Special Tools (205-126 And 205-072-02)

Courtesy of FORD MOTOR CO.

NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal.

Using the special tool, remove the crankshaft front oil seal.

Fig 44: Identifying Special Tool (303-409) And Crankshaft Front Oil Seal

Courtesy 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.

Remove and discard the CKP sensor.

Fig 45: Locating CKP Sensor

Courtesy of FORD MOTOR CO.

Remove the bolts and the engine front cover.

Fig 46: Locating Engine Front Cover Bolts

Courtesy of FORD MOTOR CO.

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 47: Locating Timing Chain Tensioner Bolt

Courtesy of FORD MOTOR CO.

Remove the RH timing chain guide.

Fig 48: Locating RH Timing Chain Guide

Courtesy of FORD MOTOR CO.

Remove the timing chain.

Fig 49: View Of Timing Chain

Courtesy of FORD MOTOR CO.

Remove the bolts and the LH timing chain guide.

Fig 50: Identifying Bolts And LH Timing Chain Guide

Courtesy 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.

Using the flats on the camshaft to prevent camshaft rotation, remove the bolts and the camshaft sprockets.

Fig 51: Locating Cam Holding Area And Sprocket Bolt

Courtesy of FORD MOTOR CO.

Remove the oil pump chain tensioner.
1. Release the tension on the tensioner spring.
2. Remove the tensioner and the shoulder bolts.

Fig 52: Locating Shoulder Bolts & Tensioner

Courtesy 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.

Remove the oil pump chain and sprockets.
1. Remove the bolt.
2. Remove the chain and sprockets.

Fig 53: Identifying Chain & Sprockets

Courtesy of FORD MOTOR CO.

Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.

Fig 54: Locating Camshaft Lobe

Courtesy 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.

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.

Fig 55: Identifying Loosening Sequence Of Camshaft Bearing Bolts

Courtesy of FORD MOTOR CO.

Remove the cylinder head.
- Remove and discard the cylinder head bolts.
- Remove the cylinder head.
- Remove and discard the cylinder head gasket.

Fig 56: Locating Cylinder Head Bolts

Courtesy of FORD MOTOR CO.

Remove the cylinder head alignment dowels.

Fig 57: Identifying Cylinder Head Alignment Dowels

Courtesy of FORD MOTOR CO.

Remove the bolts and the oil pan.

Fig 58: Locating Oil Pan Bolts

Courtesy of FORD MOTOR CO.

Remove the bolts and the rear crankshaft seal.

Fig 59: Locating Rear Crankshaft Seal Bolts

Courtesy of FORD MOTOR CO.

Remove the bolts, oil pump pickup tube and gasket.

Fig 60: Locating Oil Pump Pickup Tube Bolts

Courtesy of FORD MOTOR CO.

Remove the bolts and the oil pump.

Fig 61: Locating Oil Pump Assembly & Bolts

Courtesy of FORD MOTOR CO.

Remove the bolts and the block-off plate.

Fig 62: Block-Off Plate & Bolts
Courtesy of FORD MOTOR CO.
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 63: Locating Crankshaft TDC Timing Peg
Courtesy of FORD MOTOR CO.
Mark the balancer unit front shafts on the top for reference that the balancer unit is at TDC .

Fig 64: Locating Balancer Unit Front Shaft Marks
Courtesy of FORD MOTOR CO.

NOTE: Due to the precision interior construction of the balancer unit, it should not be disassembled.

Fig 65: Locating Balancer Unit Bolts

Courtesy of FORD MOTOR CO.

Remove the 4 bolts and the balancer unit.
Remove the Crankshaft TDC Timing Peg.

Fig 66: Locating Crankshaft TDC Timing Peg
Courtesy of FORD MOTOR CO.
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.

NOTE: Clearly mark the connecting rods, connecting rod caps and connecting rod bearings in numerical order for correct orientation for reassembly.

Fig 67: Locating Connecting Rod Cap Bolts

Courtesy of FORD MOTOR CO.

Remove the connecting rod cap bolts and cap.

NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

Fig 68: Locating Connecting Rod Installer

Courtesy of FORD MOTOR CO.

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.
Remove the bolts in the sequence shown.
1. Remove the main bearing beam.
2. Discard the bolts.
Fig 69: Main Bearing Beam Bolts Removal Sequence
Courtesy of FORD MOTOR CO.
Remove the crankshaft from the engine block.

Fig 70: Locating Crankshaft On Engine Block
Courtesy of FORD MOTOR CO.

NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.

Fig 71: Locating Main Bearings

Courtesy of FORD MOTOR CO.

Remove the main bearings from the main bearing beam.

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 72: Locating Main Bearings

Courtesy of FORD MOTOR CO.

Remove the main bearings from the cylinder block.

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 73: Locating Oil Squirters

Courtesy of FORD MOTOR CO.

Remove the 4 oil squirters.
Inspect the cylinder block, main bearing beam, pistons and connecting rods. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION