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 4 (Engine - 2.3L - (Hybrid)) >> Disassembly >> Engine >> Special Tool(s)

Special Tool(s)

WARNING: This page is about a different variant/trim than selected.
SPECIAL TOOL(S) 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 engine assembly in this article.
  1. Remove the 6 bolts and the flywheel.
    Fig 1: Removing Bolts And Flywheel
    G03897959Courtesy of FORD MOTOR CO.
  2. Mount the engine on a suitable stand.
  3. Disconnect the crankshaft position (CKP) sensor electrical connector.
    Fig 2: Disconnecting Crankshaft Position (CKP) Sensor Electrical Connector
    G03897961Courtesy of FORD MOTOR CO.
  4. Remove the bolt and the engine wiring harness connector bracket.
    Fig 3: Removing Bolt And Engine Wiring Harness Connector Bracket
    G03898874Courtesy of FORD MOTOR CO.
  5. Detach the engine wiring harness pin-type retainer.
    Fig 4: Removing Engine Wiring Harness Pin-Type Retainer
    G03898875Courtesy of FORD MOTOR CO.
  6. Remove the 3 bolts and the accessory drive belt tensioner.
    Fig 5: Removing Bolts
    G03898876Courtesy of FORD MOTOR CO.
  7. Disconnect the coil-on-plug and camshaft position (CMP) sensor electrical connectors.
    Fig 6: Disconnecting (CMP) Sensor Electrical Connectors
    G03897994Courtesy of FORD MOTOR CO.
  8. Position the rubber boot aside and disconnect the cylinder head temperature (CHT) sensor electrical connector.
    Fig 7: Disconnecting Cylinder Head Temperature (CHT) Sensor Electrical Connector
    G03897996Courtesy of FORD MOTOR CO.
  9. If equipped, disconnect the block heater electrical connector.
    Fig 8: Locating Block Heater Electrical Connector
    G03897864Courtesy of FORD MOTOR CO.
  10. Disconnect the radio ignition interference capacitor electrical connector.
    Fig 9: Disconnecting Electrical Connector
    G03898880Courtesy of FORD MOTOR CO.
  11. Disconnect the exhaust gas recirculation (EGR) valve electrical connector and remove the engine control wiring harness from the engine.
    Fig 10: Disconnecting (EGR) Valve Electrical Connector
    G03898881Courtesy of FORD MOTOR CO.
  12. Remove the 3 bolts and the coolant pump pulley.
    Fig 11: Removing Bolts And Coolant Pump Pulley
    G03897969Courtesy of FORD MOTOR CO.
  13. Remove the 3 bolts and the coolant pump.
    Fig 12: Removing Bolts And Coolant Pump
    G03897970Courtesy of FORD MOTOR CO.
  14. Disconnect the coolant hose.
    Fig 13: Disconnecting Coolant Hose
    G03898884Courtesy of FORD MOTOR CO.
  15. Remove the 3 bolts and the thermostat housing.
    Fig 14: Removing Bolts And Thermostat Housing
    G03898885Courtesy of FORD MOTOR CO.
  16. Disconnect the coolant hose.
    Fig 15: Disconnecting Coolant Hose
    G03897997Courtesy of FORD MOTOR CO.
  17. Remove the bolt and the knock sensor (KS).
    Fig 16: Removing Bolt And Knock Sensor
    G03898000Courtesy of FORD MOTOR CO.
  18. Remove the 8 bolts and the crankcase vent oil separator.
    Fig 17: Removing Bolts And Crankcase Vent Oil Separator
    G03898001Courtesy of FORD MOTOR CO.
  19. Remove the 4 bolts and the oil filter adapter. Discard the gasket.
    Fig 18: Removing Bolts And Oil Filter Adapter
    G03898889Courtesy of FORD MOTOR CO.
  20. Disconnect and remove the coolant hoses.
    Fig 19: Removing Coolant Hoses
    G03898890Courtesy of FORD MOTOR CO.
  21. If equipped, remove the block heater.
    Fig 20: Identifying Block Heater
    G03898002Courtesy of FORD MOTOR CO.
  22. Remove the engine cover studs.
    Fig 21: Removing Engine Cover Studs
    G03898892Courtesy of FORD MOTOR CO.
  23. Remove the crankcase vent tube and the coil-on-plugs.
    Fig 22: Removing Crankcase Vent Tube And Coil-On-Plugs
    G03898003Courtesy of FORD MOTOR CO.
  24. Remove the spark plugs and the CHT sensor.
    • Discard the CHT sensor.
      Fig 23: Removing Spark Plugs
      G03898004Courtesy of FORD MOTOR CO.
  25. Remove the bolts and the valve cover.
    Fig 24: Removing Bolts And Valve Cover
    G03898005Courtesy of FORD MOTOR CO.
    26. 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.
    27. 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 25: Identifying Special Tool
    G03898006Courtesy of FORD MOTOR CO.
  27. Install the special tool in the slots on the rear of both camshafts.
  28. Remove the engine plug bolt.
    Fig 26: Locating Engine Plug Bolt
    G04319319Courtesy of FORD MOTOR CO.
    29. NOTE: Only turn the engine in the normal direction of rotation.
    NOTE: Installing the special tool in this step will prevent the engine from being rotated in the clockwise direction.
    Fig 27: Identifying Special Tool
    G03897707Courtesy of FORD MOTOR CO.
  29. Install the special tool.
  30. Install the special tool.
    Fig 28: Installing Special Tool
    G03898009Courtesy of FORD MOTOR CO.
    31. CAUTION: Failure to hold the crankshaft pulley in place while loosening the bolt can result in damage to the engine.
  31. Remove the crankshaft pulley.
    • Remove the crankshaft pulley bolt and washer.
    • Remove the crankshaft pulley.
      Fig 29: Removing Crankshaft Pulley Using Special Tool
      G03898010Courtesy of FORD MOTOR CO.
    32. CAUTION: Use care not to damage the engine front cover or the crankshaft when removing the seal.
    Fig 30: Removing Crankshaft Front Oil Seal Using Special Tool
    G03898011Courtesy of FORD MOTOR CO.
  32. Using the special tool, remove the crankshaft front oil seal.
    33. NOTE: Whenever the CKP sensor is removed, a new one must be installed using the alignment jig supplied with the new part.
    Fig 31: Removing Bolt And CKP Sensor
    G03898012Courtesy of FORD MOTOR CO.
  33. Remove and discard the CKP sensor.
  34. Remove the bolts and the engine front cover.
    Fig 32: Removing Engine Front Cover Bolts
    G03897743Courtesy of FORD MOTOR CO.
  35. 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 33: Removing Bolts And Timing Chain Tensioner
      G03897777Courtesy of FORD MOTOR CO.
  36. Remove the RH timing chain guide.
    Fig 34: Identifying Timing Chain Guide
    G03897778Courtesy of FORD MOTOR CO.
  37. Remove the timing chain.
    Fig 35: Identifying Timing Chain
    G03897779Courtesy of FORD MOTOR CO.
  38. Remove the bolts and the LH timing chain guide.
    Fig 36: Identifying LH Timing Chain Guide And Bolts
    G03897780Courtesy of FORD MOTOR CO.
    39. CAUTION: Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation. Damage to the tool or the camshaft can occur.
    Fig 37: Locating Cam Holding Area And Sprocket Bolt
    G03897781Courtesy of FORD MOTOR CO.
  39. Using the flats on the camshaft to prevent camshaft rotation, remove the bolts and the camshaft sprockets.
  40. 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 38: Removing Tensioner And Shoulder Bolt
      G03898019Courtesy of FORD MOTOR CO.
    41. 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.
  41. Remove the oil pump chain and sprockets.
    1. Remove the bolt.
    2. Remove the chain and sprockets.
      Fig 39: Removing Oil Pump Chain And Sprockets
      G03898020Courtesy of FORD MOTOR CO.
  42. Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.
    Fig 40: Positioning Camshaft Lobes
    G03898791Courtesy of FORD MOTOR CO.
    43. CAUTION: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.
  43. Remove the camshafts from the engine.
    • Loosen the camshaft bearing bolts in the sequence shown in Fig 41, one turn at a time. Repeat until all the tension is released.
    • Remove the camshaft bearing caps.
    • Remove the camshafts.
      Fig 41: Removing Camshaft Bearing Caps
      G03897808Courtesy of FORD MOTOR CO.
  44. Remove the cylinder head.
    • Remove and discard the cylinder head bolts.
    • Remove the cylinder head.
    • Remove and discard the cylinder head gasket.
      Fig 42: Removing Cylinder Head Bolts
      G03898023Courtesy of FORD MOTOR CO.
  45. Remove the cylinder head alignment dowels.
    Fig 43: Identifying Cylinder Head Alignment Dowels
    G03898024Courtesy of FORD MOTOR CO.
  46. Remove the bolts and the oil pan.
    Fig 44: Removing Bolts And Oil Pan
    G03898915Courtesy of FORD MOTOR CO.
  47. Remove the bolts and the rear crankshaft seal.
    Fig 45: Removing Bolts
    G03898026Courtesy of FORD MOTOR CO.
  48. Remove the bolts, oil pump pickup tube and gasket.
    Fig 46: Removing Bolts
    G03898027Courtesy of FORD MOTOR CO.
  49. Remove the bolts and the oil pump.
    Fig 47: Removing Bolts And Oil Pump
    G03898028Courtesy of FORD MOTOR CO.
  50. Remove the bolts and the block-off plate.
    Fig 48: Removing Bolts And Block-Off Plate
    G03898919Courtesy of FORD MOTOR CO.
scientia non olet · About LEMON Manuals