Section 1664 (Engine Mechanical - 2.5L (Hybrid)): Disassembly: Engine
WARNING: This page is about a different car, the 2011 Mercury Milan, 2011 Lincoln MKZ, and 2011 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL(S)
| Alignment Plate, Camshaft 303-465 (T94P-6256-CH) |
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| Engine Stand 014-00232 or equivalent |
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| 2,200# Floor Crane, Fold Away 300-OTC1819E or equivalent |
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| Holding Tool, Crankshaft Damper 303-1416 |
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| Installer, Connecting Rod 303-462 (T94P-6136-AH) |
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| Remover, Oil Seal 303-409 (T92C-6700-CH) |
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| Spreader Bar 303-D089 (D93P-6001-A3) or equivalent |
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| Timing Peg, Crankshaft TDC 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 the pulley bolt is loosened. 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 or 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 service information.
- Remove the 6 bolts and the flywheel.
- Mount the engine on a suitable engine stand.
- If equipped, disconnect the engine block heater.
- Disconnect the Heated Oxygen Sensor (HO2S) electrical connector.
- Detach the connector from the engine wiring harness connector bracket.
- Disconnect the Catalyst Monitor Sensor (CMS) electrical connector.
- Disconnect the Crankshaft Position (CKP) sensor electrical connector.
- Remove the bolt and the engine wiring harness connector bracket.
- Detach the 2 engine wiring harness pin-type retainers.
- Remove the 6 bolts and the catalytic converter manifold heat shield.
- Remove the 2 catalytic converter manifold bracket-to-engine block bolts.
- Remove the 7 nuts and the catalytic converter manifold.
- Discard the nuts and the catalytic converter manifold gasket.
- Remove and discard the 7 cylinder head studs.
- Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt.
- Detach the vehicle high voltage electrical system electrical connector retainer from the accessory drive belt tensioner.
- Remove the 3 bolts and the accessory drive belt tensioner.
- Disconnect the electronic throttle control electrical connector.
- Disconnect the Evaporative Emission (EVAP) canister purge valve electrical connector.
- Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
- Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector.
- Disconnect the Knock Sensor (KS) electrical connector and detach the electrical connector pin-type retainer from the intake manifold.
- Disconnect the A/C compressor electrical connector.
- Remove the 3 bolts and the A/C compressor.
- Disconnect the Variable Camshaft Timing (VCT) oil control solenoid electrical connector and detach the wiring harness retainer from the valve cover stud bolt.
- Detach the 3 wire harness pin-type retainers.
- Detach the 2 auxiliary coolant pump wiring retainers and the lower radiator hose retainer.
- Disconnect the auxiliary coolant pump hose and the upper radiator hose.
- Disconnect the EGR coolant hose and the auxiliary coolant pump hose.
- Remove the upper radiator hose and the auxiliary coolant pump as an assembly.
- Remove the 2 bolts and the A/C compressor bracket.
- Disconnect the vacuum hose from the intake manifold.
- Remove the 2 bolts, the nut and the vacuum pump assembly.
- Detach the 3 wire harness pin-type retainers from the intake manifold.
- Remove the 7 bolts and position the intake manifold aside to access the PCV hose connector.
- Squeeze the 2 PCV hose connector tabs and disconnect the PCV hose from the intake manifold.
- Remove the intake manifold.
- Remove the EGR tube.
- Disconnect the 4 fuel injector electrical connectors, radio capacitor electrical connector and the Camshaft Position (CMP) sensor electrical connector.
- Disconnect the 4 coil-on-plug electrical connectors.
- Position the rubber boot aside and disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
- Disconnect the EGR valve electrical connector and detach the 2 wiring harness retainers from the valve cover and stud bolt.
- Remove the engine control wiring harness from the engine.
- Remove the fuel rail insulator.
- Remove the nut and the radio capacitor.
- Remove the 2 stud bolts and the fuel rail with the fuel injectors.
- Remove the 3 bolts and the coolant pump pulley.
- Remove the 3 bolts and the coolant pump.
- Remove the 3 bolts and the thermostat housing.
- Disconnect the bypass hose.
- Remove the bolt and the KS.
- Remove the 8 bolts and the crankcase vent oil separator.
- Remove the 4 bolts and the oil filter adapter.
- Discard the gasket.
- If equipped, remove the block heater.
- Remove the crankshaft vent tube.
- Remove the 2 engine cover studs (one shown in illustration).
- Remove the 4 stud bolts and the coil-on-plugs from the valve cover.
- Remove the oil level indicator.
- Remove the CHT sensor.
- Remove the bolts and the valve cover.
- 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.
- Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
- Remove the engine plug bolt.
- Install the Crankshaft TDC Timing Peg.
- Using the Crankshaft Damper Holding Tool 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.
- Using the Oil Seal Remover, remove the crankshaft front oil seal.
- Remove the 2 bolts and the CKP sensor.
- Remove the bolts and the engine front cover.
- Compress the timing chain tensioner in the following sequence.
- Using a small pick, release and hold the ratchet mechanism.
- While holding the ratchet mechanism in the released position, compress the tensioner by pushing the timing chain arm toward the tensioner.
- Insert a paper clip into the hole to retain the tensioner.
- Remove the 2 bolts and timing chain tensioner.
- Remove the RH timing chain guide.
- Remove the timing chain.
- Remove the bolts and the LH timing chain guide.
- Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the exhaust camshaft sprocket.
- Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the intake camshaft phaser and sprocket.
- Remove the oil pump chain tensioner.
- Release the tension on the tensioner spring.
- Remove the tensioner and the shoulder bolts.
- Remove the oil pump chain and sprockets.
- Remove the bolt.
- Remove the chain and sprockets.
- Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.
- Remove the bolt and the Variable Camshaft Timing (VCT) solenoid.
- Remove the plug and the VCT system oil filter from the intake camshaft thrust cap.
- Remove the camshafts from the engine.
- Loosen the camshaft bearing bolts in the sequence shown in illustration, one turn at a time. Repeat until all the tension is released.
- Remove the camshaft bearing caps.
- Remove the camshafts.
- Remove and inspect the valve tappets. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
- Remove the cylinder head.
- Remove and discard the cylinder head bolts.
- Remove the cylinder head.
- Remove and discard the cylinder head gasket.
- Support the cylinder heads on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
- Remove the cylinder head alignment dowels.
- Remove the bolts and the oil pan.
- Remove the bolts and the crankshaft rear oil seal with retainer.
- Remove the bolts, oil pump pickup tube and gasket.
- Remove the bolts and the oil pump.
- Remove the bolts and the block-off plate.
- Make sure the Crankshaft TDC Timing Peg is still installed and the engine is still at Top Dead Center (TDC).
- Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg.
- Mark the balancer unit front shafts on the top for reference that the balancer unit is at TDC.
- Remove the 4 bolts and the balancer unit.
- Remove the Crankshaft TDC Timing Peg.
- 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.
- Remove the connecting rod cap bolts and cap.
- 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 in illustration.
- Remove the main bearing beam.
- Discard the bolts.
- Remove the crankshaft from the engine block.
- Remove the main bearings from the main bearing beam.
- Remove the main bearings from the cylinder block.
- 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 article.
NOTE:
The cylinder head side of the intake manifold is showing the location of the 7 bolts.
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.
NOTE:
The Camshaft Alignment Plate 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 Camshaft Alignment Plate 303-465 cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.
NOTE:
The Crankshaft TDC Timing Peg 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.
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 Crankshaft Damper Holding 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:
Use care not to damage the engine front cover or the crankshaft when removing the seal.
NOTE:
Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation. Damage to the tool or the camshaft can occur.
NOTE:
The Camshaft Alignment Plate 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
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.
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.
NOTE:
If the camshafts and valve tappets are to be reused, mark the location of the valve tappets to make sure they are assembled in their original positions.
NOTE:
The number on the valve tappets only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm.
NOTE:
Due to the precision interior construction of the balancer unit, it should not be disassembled.
NOTE:
Clearly mark the connecting rods, connecting rod caps and connecting rod bearings in numerical order for correct orientation for reassembly.
NOTE:
Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
NOTE:
If the main bearings are being reused, mark them in order for correct orientation and reassembly.
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.
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.