LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2005 >> Escape Base, 3.0 1, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 3 (Engine - 2.3L - (Except Hybrid)) >> Disassembly >> Engine

Section 3 (Engine - 2.3L - (Except Hybrid)): Disassembly: Engine

WARNING: This page is about a different variant/trim than selected.
SPECIAL TOOL DESCRIPTION

G03898823
 Heavy Duty Floor Crane 014-00071 or equivalent
G03898617
 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
G03950680
 Engine Stand 014-00232 or equivalent
G03898747
 Alignment Plate, Camshaft 303-465 (T94P-6256-CH)
G03897953
 Timing Peg, Crankshaft 303-507
G03898935
 Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A)
G03898936
 Adapter for 205-126 (205-072-02)
G03898751
 Remover, Oil Seal 303 - 409 (T92C-6700-CH)
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: 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. Therefore, the engine must be retimed each time the damper is removed. Otherwise severe engine damage can occur.
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 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 these instructions may result in personal injury.
    CAUTION: Loosen the bolts evenly to prevent pressure plate damage.
    Fig 1: Removing Bolts, Clutch Pressure Plate And Clutch Disc
    G03897957Courtesy of FORD MOTOR CO.
  1. Remove the bolts, clutch pressure plate and clutch disc.
  2. Remove the starter motor isolator.
    Fig 2: Removing Starter Motor Isolator
    G03897958Courtesy of FORD MOTOR CO.
  3. Remove the bolts and the flywheel.
    Fig 3: Removing Bolts And Flywheel
    G03897959Courtesy of FORD MOTOR CO.

    4. Vehicles with automatic transaxle 

  4. Remove the bolts and the flexplate.
    Fig 4: Removing Bolts And Flexplate
    G03897960Courtesy of FORD MOTOR CO.

    5. All vehicles 

  5. Mount the engine on a suitable stand.
  6. Disconnect the crankshaft position (CKP) sensor electrical connector.
    Fig 5: Disconnecting Crankshaft Position Sensor Electrical Connector
    G03897961Courtesy of FORD MOTOR CO.
  7. Remove the nut and disconnect the generator electrical connections.
    Fig 6: Removing Nut And Disconnect Generator Electrical Connections
    G03897962Courtesy of FORD MOTOR CO.
  8. Remove the 2 lower catalytic converter bolts.
    Fig 7: Removing Lower Catalytic Converter Bolts
    G03897963Courtesy of FORD MOTOR CO.
  9. Remove the 6 heat shield bolts and the heat shield.
    Fig 8: Removing Heat Shield Bolts And Heat Shield
    G03897964Courtesy of FORD MOTOR CO.
  10. Remove and discard the 7 exhaust manifold nuts.
    Fig 9: Removing Exhaust Manifold Nuts
    G03897965Courtesy of FORD MOTOR CO.
  11. Remove the catalytic converter and discard the exhaust manifold gasket.
  12. Remove the bolts and the generator.
    Fig 10: Removing Bolts And Generator
    G03897966Courtesy of FORD MOTOR CO.
  13. Loosen the bolt and remove the accessory drive belt idler pulley.
    Fig 11: Removing Accessory Drive Belt Idler Pulley
    G03897967Courtesy of FORD MOTOR CO.
  14. If equipped, loosen the bolt and remove the accessory drive belt idler pulley.
    Fig 12: Removing Accessory Drive Belt Idler Pulley
    G03897968Courtesy of FORD MOTOR CO.
  15. Remove the bolts and the coolant pump pulley.
    Fig 13: Removing Bolts And Coolant Pump Pulley
    G03897969Courtesy of FORD MOTOR CO.
  16. Remove the bolts and the coolant pump.
    Fig 14: Removing Bolts And Coolant Pump
    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.
      Fig 15: Removing Engine Vacuum Tube
      G03897971Courtesy of FORD MOTOR CO.
  18. Detach the 2 wiring harness retainers and position the harness aside.
    Fig 16: Detaching Wiring Harness Retainers
    G03897972Courtesy of FORD MOTOR CO.
  19. Disconnect the oil cooler hoses.
    Fig 17: Disconnecting Oil Cooler Hoses
    G03897973Courtesy of FORD MOTOR CO.
  20. Remove the bolts and the thermostat housing assembly.
    Fig 18: Removing Bolts And Thermostat Housing Assembly
    G03897974Courtesy of FORD MOTOR CO.
  21. Remove the bolts and the oil level indicator.
    Fig 19: Removing Bolts And Oil Level Indicator
    G03897975Courtesy of FORD MOTOR CO.
  22. Disconnect the oil pressure sensor electrical connector.
    Fig 20: Disconnecting Oil Pressure Sensor Electrical Connector
    G03897976Courtesy of FORD MOTOR CO.
  23. Remove the oil filter, 4 bolts and the oil filter adapter.
    • Discard the oil filter and gasket.
      Fig 21: Removing Oil Filter, Bolts And Oil Filter Adapter
      G03897977Courtesy of FORD MOTOR CO.
    24. 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.
    Fig 22: Removing Bolt And Capacitor
    G03897978Courtesy of FORD MOTOR CO.
  26. Detach the 2 wiring harness retainers.
    Fig 23: Detaching Wiring Harness Retainers
    G03897979Courtesy of FORD MOTOR CO.
  27. Disconnect the knock sensor (KS) and detach the 2 wiring harness retainers.
    Fig 24: Disconnecting Knock Sensor And Detach Wiring Harness Retainers
    G03897980Courtesy of FORD MOTOR CO.
  28. Disconnect the temperature manifold absolute pressure (TMAP) electrical connector.
    Fig 25: Disconnecting Temperature Manifold Absolute Pressure Electrical Connector
    G03897981Courtesy of FORD MOTOR CO.
  29. Disconnect the idle air control (IAC) motor electrical connector.
    Fig 26: Disconnecting Idle Air Control Motor Electrical Connector
    G03897982Courtesy of FORD MOTOR CO.
  30. Disconnect the swirl control valve electrical connector.
    Fig 27: Disconnecting Swirl Control Valve Electrical Connector
    G03897983Courtesy of FORD MOTOR CO.
  31. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum tube.
    Fig 28: Disconnecting Fuel Rail Pressure And Temperature Sensor Electrical Connector And Vacuum Tube
    G03897984Courtesy of FORD MOTOR CO.
  32. Disconnect the throttle position (TP) sensor electrical connector.
    Fig 29: Disconnecting Throttle Position Sensor Electrical Connector
    G03897985Courtesy of FORD MOTOR CO.
    33. NOTE: There are 3 different size bolts used. Mark the location of the bolts to ensure installation in the correct locations.
    Fig 30: Removing Intake Manifold Bolts
    G03897986Courtesy of FORD MOTOR CO.
  33. Remove the bolts and position the intake manifold aside.
  34. Disconnect the positive crankcase ventilation (PCV) hose and remove the intake manifold.
    Fig 31: Disconnecting Positive Crankcase Ventilation Hose
    G03897987Courtesy of FORD MOTOR CO.
  35. Remove the exhaust gas recirculation (EGR) tube.
    Fig 32: Removing Exhaust Gas Recirculation Tube
    G03897988Courtesy of FORD MOTOR CO.
  36. Disconnect the 4 fuel injector electrical connectors. Detach the 2 wiring harness retainers.
    Fig 33: Disconnecting Fuel Injector Electrical Connectors
    G03897989Courtesy of FORD MOTOR CO.
  37. Remove the 2 bolts and the fuel rail with the fuel injectors.
    Fig 34: Removing Bolts And Fuel Rail With Fuel Injectors
    G03897990Courtesy of FORD MOTOR CO.
  38. Remove the fuel rail spacers.
    Fig 35: Identifying Fuel Rail Spacers
    G03897991Courtesy of FORD MOTOR CO.
  39. Detach the wiring harness retainer.
    Fig 36: Detaching Wiring Harness Retainer
    G03897992Courtesy of FORD MOTOR CO.
  40. Disconnect the EGR valve and radio interference capacitor electrical connectors. Detach the wiring harness retainer.
    Fig 37: Disconnect EGR Valve And Radio Interference Capacitor Electrical Connectors
    G03897993Courtesy of FORD MOTOR CO.
  41. Disconnect the coil-on-plug and camshaft position (CMP) sensor electrical connectors.
    Fig 38: Disconnecting Coil-On-Plug And Camshaft Position Sensor Electrical Connectors
    G03897994Courtesy of FORD MOTOR CO.
  42. Detach the wiring harness retainer.
    Fig 39: Detaching Wiring Harness Retainer
    G03897995Courtesy 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.
    Fig 40: Disconnecting Cylinder Head Temperature Sensor Electrical Connector
    G03897996Courtesy of FORD MOTOR CO.
  44. Disconnect the coolant hose.
    Fig 41: Disconnecting Coolant Hose
    G03897997Courtesy of FORD MOTOR CO.
  45. Disconnect and remove the coolant hose.
    Fig 42: Removing Coolant Hose
    G03897998Courtesy of FORD MOTOR CO.
  46. Disconnect and remove the coolant hoses.
    Fig 43: Removing Coolant Hoses
    G03897999Courtesy of FORD MOTOR CO.
  47. Remove the bolt and the KS.
    Fig 44: Removing Bolt And KS
    G03898000Courtesy of FORD MOTOR CO.
  48. Remove the bolts and the crankcase vent oil separator.
    Fig 45: Removing Bolts And Crankcase Vent Oil Separator
    G03898001Courtesy of FORD MOTOR CO.
  49. If equipped, remove the block heater.
    Fig 46: Identifying Block Heater
    G03898002Courtesy of FORD MOTOR CO.
  50. Remove the crankcase vent tube and the coil-on-plugs.
    Fig 47: Removing Crankcase Vent Tube And Coil-On-Plugs
    G03898003Courtesy of FORD MOTOR CO.
  51. Remove the spark plugs and the CHT sensor.
    • Discard the CHT.
      Fig 48: Removing Spark Plugs And CHT Sensor
      G03898004Courtesy of FORD MOTOR CO.
  52. Remove the bolts and the valve cover.
    Fig 49: Removing Bolts And Valve Cover
    G03898005Courtesy of FORD MOTOR CO.
    53. 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.
  53. 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.
    54. 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.
    Fig 50: Identifying Special Tool
    G03898006Courtesy of FORD MOTOR CO.
  54. Install the special tool in the slots on the rear of both camshafts.
  55. Remove the engine plug bolt.
    Fig 51: Locating Engine Plug Bolt
    G04319319Courtesy of FORD MOTOR CO.
    56. 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.
    Fig 52: Installing Special Tool
    G03897737Courtesy of FORD MOTOR CO.
  56. Install the special tool.
  57. Install the special tools.
    Fig 53: Installing Special Tool (205-126)
    G03898009Courtesy of FORD MOTOR CO.
    58. CAUTION: Failure to hold the crankshaft pulley in place while loosening the bolt can result in damage to the engine.
  58. Remove the crankshaft pulley.
    • Remove the crankshaft pulley bolt and washer. Discard the bolt.
    • Remove the crankshaft pulley.
      Fig 54: Removing Crankshaft Pulley Bolt
      G03898010Courtesy of FORD MOTOR CO.
    59. CAUTION: Use care not to damage the engine front cover or the crankshaft when removing the seal.
    Fig 55: Removing Crankshaft Front Oil Seal
    G03898011Courtesy of FORD MOTOR CO.
  59. Using the special tool, remove the crankshaft front oil seal.
    60. NOTE: Whenever the CKP sensor is removed, a new one must be installed using the alignment jig supplied with the new part.
    Fig 56: Removing CKP Sensor
    G03898012Courtesy of FORD MOTOR CO.
  60. Remove and discard the CKP sensor.
  61. Remove the bolts and the engine front cover.
    Fig 57: Removing 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.
      Fig 58: Removing Bolts And Timing Chain Tensioner
      G03897777Courtesy of FORD MOTOR CO.
  63. Remove the RH timing chain guide.
    Fig 59: Identifying Timing Chain Guide
    G03897778Courtesy of FORD MOTOR CO.
  64. Remove the timing chain.
    Fig 60: Identifying Timing Chain
    G03897779Courtesy of FORD MOTOR CO.
  65. Remove the bolts and the LH timing chain guide.
    Fig 61: Identifying LH Timing Chain Guide And Bolts
    G03897780Courtesy of FORD MOTOR CO.
    66. CAUTION: Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation. Damage to the tool or the camshaft can occur.
    Fig 62: Locating Cam Holding Area And Sprocket Bolt
    G03897781Courtesy of FORD MOTOR CO.
  66. Using the flats on the camshaft to prevent camshaft rotation, remove the bolts and the camshaft sprockets.
  67. Remove the oil pump chain tensioner and guide.
    1. Release the tension on the tensioner spring.
    2. Remove the tensioner and the shoulder bolt.
    3. Remove the guide.
      Fig 63: Removing Oil Pump Chain Tensioner And Guide
      G03898019Courtesy of FORD MOTOR CO.
    68. 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.
      Fig 64: Removing Oil Pump Chain And Sprockets
      G03898020Courtesy of FORD MOTOR CO.
  69. Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.
    Fig 65: Positioning Camshaft Lobes
    G03898791Courtesy of FORD MOTOR CO.
    70. 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.
      Fig 66: Identifying Loosening 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.
      Fig 67: Removing And Discard Cylinder Head Bolts
      G03898023Courtesy of FORD MOTOR CO.
  72. Remove the cylinder head alignment dowels.
    Fig 68: Identifying Cylinder Head Alignment Dowels
    G03898024Courtesy of FORD MOTOR CO.
  73. Remove the bolts and the oil pan.
    Fig 69: Removing Bolts And Oil Pan
    G03898915Courtesy of FORD MOTOR CO.
  74. Remove the bolts and the rear crankshaft seal.
    Fig 70: Removing Bolts And Rear Crankshaft Seal
    G03898026Courtesy of FORD MOTOR CO.
  75. Remove the bolts, oil pump pickup tube and gasket.
    Fig 71: Removing Bolts, Oil Pump Pickup Tube And Gasket
    G03898027Courtesy of FORD MOTOR CO.
  76. Remove the bolts and the oil pump.
    Fig 72: Removing Bolts And Oil Pump
    G03898028Courtesy of FORD MOTOR CO.
  77. If necessary, remove the bolts and halfshaft support bracket.
    Fig 73: Removing Bolts And Halfshaft Support Bracket
    G03898029Courtesy of FORD MOTOR CO.
scientia non olet · About LEMON Manuals