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Home >> Ford >> 2005 >> Escape Hybrid, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 9 (Engine - 3.0L (4V)) >> Disassembly >> Engine >> Special Tool(s)

Special Tool(s)

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

G03990108
 Slide Hammer 307-005 (T59L-100-B)
G03889585
 Strap Wrench 303-D055 (D85L-6000-A)
G03886718
 Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH)
G03886657
 Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D)
G03898751
 Remover, Oil Seal 303-409 (T92C-6700CH)
G03898523
 Service Set, Water Pump Pulley 303-S455 (T94P-6312-AH)
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.
NOTE: For additional information, refer to the exploded view under the assembly procedure in this article.

    All vehicles 

  1. Remove the bolts and the flexplate.
    Fig 1: Removing Bolts And Flexplate
    G03898440Courtesy of FORD MOTOR CO.
  2. Using the special tools, remove and discard the crankshaft rear oil seal.
    Fig 2: Removing Crankshaft Rear Oil Seal
    G03898286Courtesy of FORD MOTOR CO.
  3. Mount the engine on a suitable stand.
  4. Detach the engine control sensor wiring connectors from the upper intake manifold.
    Fig 3: Detaching Engine Control Sensor Wiring Connectors From Upper Intake Manifold
    G03898442Courtesy of FORD MOTOR CO.
  5. Detach the wiring retainer, remove the nut and the heated oxygen sensor (HO2S) electrical connector bracket.
    Fig 4: Removing Nut And Heated Oxygen Sensor Electrical Connector Bracket
    G03898443Courtesy of FORD MOTOR CO.
  6. Disconnect the exhaust gas recirculation (EGR) vacuum regulator electrical connector and remove the nut. Detach the wiring harness retainer.
    Fig 5: Disconnecting Exhaust Gas Recirculation Vacuum Regulator Electrical Connector And Nut
    G03898444Courtesy of FORD MOTOR CO.
  7. Disconnect the knock sensor (KS) electrical connector.
    Fig 6: Disconnecting Knock Sensor Electrical Connector
    G03898445Courtesy of FORD MOTOR CO.
  8. Remove the nuts and the engine control wire harness.
    Fig 7: Removing Nuts And Engine Control Wire Harness
    G03898446Courtesy of FORD MOTOR CO.
  9. Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor electrical connectors, and detach the wiring retainer.
    Fig 8: Disconnecting Idle Air Control Valve And Throttle Position Sensor Electrical Connectors
    G03898447Courtesy of FORD MOTOR CO.
  10. Remove the positive crankcase ventilation (PCV) tube.
    Fig 9: Removing Positive Crankcase Ventilation Tube
    G03898448Courtesy of FORD MOTOR CO.
  11. Disconnect the vacuum tube fittings from the EGR valve, EGR vacuum regulator and the intake manifold.
    Fig 10: Disconnecting Vacuum Tube Fittings From EGR Valve, EGR Vacuum Regulator And Intake Manifold
    G03898449Courtesy of FORD MOTOR CO.
  12. Disconnect the throttle body coolant hose.
    Fig 11: Disconnecting Throttle Body Coolant Hose
    G03898450Courtesy of FORD MOTOR CO.
  13. Remove the bolts and upper intake manifold.
    • Discard the gaskets.
      Fig 12: Removing Bolts And Upper Intake Manifold
      G03898451Courtesy of FORD MOTOR CO.
  14. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
    Fig 13: Disconnecting Engine Coolant Temperature Sensor Electrical Connector
    G03898452Courtesy of FORD MOTOR CO.
  15. Disconnect the RH coil-on-plug electrical connectors and detach the wiring retainer.
    Fig 14: Disconnecting RH Coil-On-Plug Electrical Connectors
    G03898453Courtesy of FORD MOTOR CO.
  16. Disconnect the radio interference capacitor electrical connector and detach the wiring retainers.
    Fig 15: Disconnecting Radio Interference Capacitor Electrical Connector
    G03898454Courtesy of FORD MOTOR CO.
  17. Disconnect the LH coil-on-plug electrical connectors and detach the wiring retainers.
    Fig 16: Disconnecting LH Coil-On-Plug Electrical Connectors
    G03898455Courtesy of FORD MOTOR CO.
  18. Disconnect the camshaft position sensor (CMP) and oil pressure sensor electrical connectors and detach the wiring retainers.
    Fig 17: Disconnecting Camshaft Position Sensor And Oil Pressure Sensor Electrical Connectors
    G03898456Courtesy of FORD MOTOR CO.
  19. Disconnect the crankshaft position (CKP) sensor electrical connector and detach the wiring retainers.
    Fig 18: Disconnecting Crankshaft Position Sensor Electrical Connector
    G03898457Courtesy of FORD MOTOR CO.
  20. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum tube.
    • Remove the engine vacuum harness.
      Fig 19: Disconnecting Fuel Rail Pressure And Temperature Sensor Electrical Connector And Vacuum Tube
      G03898458Courtesy of FORD MOTOR CO.
  21. Disconnect the fuel injector electrical connectors and remove the fuel charging wiring harness.
    Fig 20: Disconnecting Fuel Injector Electrical Connectors
    G03898459Courtesy of FORD MOTOR CO.
  22. Remove the bolts and the lower intake manifold.
    • Discard the gaskets.
      Fig 21: Removing Bolts And Lower Intake Manifold
      G03898460Courtesy of FORD MOTOR CO.
    23. CAUTION: When removing the coil-on-plugs, a slight twisting motion will break the seal and ease removal.
    NOTE: LH shown, RH similar.
    Fig 22: Removing Bolts And Coil-On-Plugs
    G03898461Courtesy of FORD MOTOR CO.
  23. Remove the bolts and the 6 coil-on-plugs.
  24. Remove the nut and the radio interference capacitor.
    Fig 23: Removing Nut And Radio Interference Capacitor
    G03898462Courtesy of FORD MOTOR CO.
  25. Remove the bolts and the RH valve cover.
    • Discard the gasket.
      Fig 24: Removing Bolts And RH Valve Cover
      G03898463Courtesy of FORD MOTOR CO.
  26. Remove the bolt and the engine lift bracket.
    Fig 25: Removing Bolt And Engine Lift Bracket
    G03898464Courtesy of FORD MOTOR CO.
  27. Remove the nuts and the coolant pump belt cover.
    Fig 26: Removing Nuts And Coolant Pump Belt Cover
    G03898465Courtesy of FORD MOTOR CO.
  28. Remove the bolts and the LH valve cover.
    • Discard the gasket.
      Fig 27: Removing Bolts And LH Valve Cover
      G03898466Courtesy of FORD MOTOR CO.
  29. Remove the nuts, the LH exhaust manifold and the gasket.
    • Discard the gasket.
      Fig 28: Removing Nuts, LH Exhaust Manifold And Gasket
      G03898467Courtesy of FORD MOTOR CO.

    30. 4x2 vehicles 

  30. Remove the nuts, the RH exhaust manifold and the gasket.
    • Discard the gasket.
      Fig 29: Removing Nuts, RH Exhaust Manifold And Gasket
      G03898468Courtesy of FORD MOTOR CO.
  31. Remove the bolts and the halfshaft support bracket.
    Fig 30: Removing Bolts And Halfshaft Support Bracket
    G03898469Courtesy of FORD MOTOR CO.

    32. All vehicles 

  32. If equipped, disconnect the coolant hoses and detach the hoses from the retainer.
    • Remove the coolant hoses.
      Fig 31: Removing Coolant Hoses
      G03898470Courtesy of FORD MOTOR CO.
  33. Remove and discard the oil filter.
    Fig 32: Removing Oil Filter
    G03898471Courtesy of FORD MOTOR CO.
    34. CAUTION: A new oil cooler must be installed or severe damage to the engine can occur.
    Fig 33: Removing Oil Cooler
    G03898472Courtesy of FORD MOTOR CO.
  34. If equipped, remove and discard the oil cooler.
  35. Cut and remove the coolant pump belt.
    Fig 34: Removing Coolant Pump Belt
    G03898473Courtesy of FORD MOTOR CO.
  36. Disconnect the hoses.
    Fig 35: Disconnecting Hoses
    G03898474Courtesy of FORD MOTOR CO.
  37. Remove the 3 bolts and the coolant pump.
    Fig 36: Removing Bolts And Coolant Pump
    G03898355Courtesy of FORD MOTOR CO.
  38. Disconnect the hoses and remove the coolant tube.
    Fig 37: Removing Coolant Tube
    G03898476Courtesy of FORD MOTOR CO.
  39. Remove the nut, bolt and the coolant bypass tube.
    Fig 38: Removing Nut, Bolt And Coolant Bypass Tube
    G03898477Courtesy of FORD MOTOR CO.
  40. Remove the stud bolt and the oil level indicator and tube.
    • Remove and discard the O-ring seal.
      Fig 39: Removing Stud Bolt And Oil Level Indicator And Tube
      G03898478Courtesy of FORD MOTOR CO.
  41. Remove the bolts, studs and the oil pan.
    • Discard the gasket.
      Fig 40: Removing Bolts, Studs And Oil Pan
      G03898479Courtesy of FORD MOTOR CO.
  42. Remove the bolts, nut and the oil pump screen and pickup tube.
    Fig 41: Removing Bolts, Nut And Oil Pump Screen And Pickup Tube
    G03898362Courtesy of FORD MOTOR CO.
  43. Remove and discard the O-ring seal.
    Fig 42: Locating O-Ring Seal
    G03898481Courtesy of FORD MOTOR CO.
  44. Remove the nuts and the oil pan baffle.
    Fig 43: Removing Nuts And Oil Pan Baffle
    G03898482Courtesy of FORD MOTOR CO.
  45. Remove the oil pressure sender and, if equipped, the block heater.
    Fig 44: Removing Oil Pressure Sender And Block Heater
    G03898483Courtesy of FORD MOTOR CO.
  46. Remove the bolt and the KS.
    Fig 45: Removing Bolt And KS
    G03898484Courtesy of FORD MOTOR CO.
  47. Use the special tool to hold the crankshaft damper and remove the bolt.
    Fig 46: Removing Crankshaft Damper Bolt
    G03898273Courtesy of FORD MOTOR CO.
  48. Using the special tool, remove the crankshaft damper.
    Fig 47: Removing Crankshaft Damper
    G03898274Courtesy of FORD MOTOR CO.
  49. Remove and discard the crankshaft front seal from the front cover.
    Fig 48: Removing Crankshaft Front Seal From Front Cover
    G03898280Courtesy of FORD MOTOR CO.
  50. Remove the bolt and the idler pulley.
    Fig 49: Removing Bolt And Idler Pulley
    G03898488Courtesy of FORD MOTOR CO.
  51. Remove the bolt and the belt tensioner.
    Fig 50: Removing Bolt And Belt Tensioner
    G03898489Courtesy of FORD MOTOR CO.
    52. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surface. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.
  52. Remove the bolts, studs and the front cover.
    • Discard the gaskets.
      Fig 51: Removing Bolts, Studs And Front Cover
      G03898490Courtesy of FORD MOTOR CO.
    53. CAUTION: This pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot stamped "30" or "30RFF" (orange in color).
    Fig 52: Identifying Ignition Pulse Wheel
    G03898322Courtesy of FORD MOTOR CO.
  53. Remove the ignition pulse wheel.
  54. Install the damper bolt.
    Fig 53: Installing Damper Bolt
    G03898296Courtesy of FORD MOTOR CO.
    55. NOTE: LH shown, RH similar.
    Fig 54: Locating Spark Plugs
    G03898297Courtesy of FORD MOTOR CO.
  55. Remove the LH and RH spark plugs.
  56. Rotate the crankshaft clockwise to position the crankshaft keyway in the 11 o'clock position and position the camshafts in the correct position. This will position the number one cylinder at top dead center (TDC).
    • Verify that the camshafts are correctly located. If not, rotate the crankshaft one additional turn and recheck.
      Fig 55: Checking Crankshaft Keyway In 11 O'Clock Position
      G03898298Courtesy of FORD MOTOR CO.
  57. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to position the RH camshafts in the neutral position.
    Fig 56: Identifying Crankshaft Keyway
    G03898299Courtesy of FORD MOTOR CO.
  58. Verify that the RH camshafts are in the neutral position.
    Fig 57: Aligning Camshafts
    G03898496Courtesy of FORD MOTOR CO.
  59. Remove the RH timing chain tensioner arm.
    1. Remove the bolts.
    2. Remove the tensioner.
      Fig 58: Removing RH Timing Chain Tensioner Arm
      G03898301Courtesy of FORD MOTOR CO.
    3. Remove the tensioner arm.
  60. Remove the bolts, RH timing chain guide and the timing chain.
    Fig 59: Removing Bolts, RH Timing Chain Guide And Timing Chain
    G03898302Courtesy of FORD MOTOR CO.
  61. Rotate the crankcase clockwise 600 degrees (1-2/3 turns) to position the crankcase key way in the 11 o'clock position. This will position the LH camshafts in the neutral position.
    Fig 60: Positioning Crankcase Key Way In 11 O'Clock Position
    G03898303Courtesy of FORD MOTOR CO.
  62. Verify the LH camshafts are in the neutral position.
    Fig 61: Aligning Camshafts
    G03955709Courtesy of FORD MOTOR CO.
  63. Remove the LH timing chain and tensioner arm.
    1. Remove the bolts.
    2. Remove the tensioner.
      Fig 62: Removing LH Timing Chain And Tensioner Arm
      G03898305Courtesy of FORD MOTOR CO.
    3. Remove the tensioner arm.
  64. Remove the LH timing chain and timing chain guide.
    Fig 63: Removing LH Timing Chain And Timing Chain Guide
    G03898306Courtesy of FORD MOTOR CO.
  65. Remove the damper bolt and the crankshaft sprockets.
    Fig 64: Removing Damper Bolt And Crankshaft Sprockets
    G03898307Courtesy of FORD MOTOR CO.
    66. CAUTION: The OEM pulley is pressed on 4.74 mm (0.18 in) past flush of the end of the camshaft. The service pulley is pressed on flush to the end of the camshaft.
    Fig 65: Removing Coolant Pump Drive Pulley
    G03898332Courtesy of FORD MOTOR CO.
  66. Using the special tools, remove the coolant pump drive pulley and discard.
    67. CAUTION: To make sure of correct sealing, do not scratch the camshaft.
    Fig 66: Removing Camshaft Oil Seal
    G03898333Courtesy of FORD MOTOR CO.
  67. Using the special tools, remove the camshaft oil seal and discard.
  68. Remove the intake camshaft oil seal retainer and discard the press-in-place gasket.
    Fig 67: Removing Intake Camshaft Oil Seal Retainer
    G03898506Courtesy of FORD MOTOR CO.
    69. CAUTION: Cylinder head camshaft journal caps and cylinder heads are numbered to verify that they are assembled in their original positions.
    NOTE: RH shown, LH similar.
    NOTE: The camshaft caps have alignment dowels.
  69. Loosen the LH and RH camshaft cap bolts in the indicated sequence and remove the camshaft caps.
    • Tap the caps lightly with a soft-faced mallet to loosen the camshaft caps.
      Fig 68: Identifying Loosening Sequence Of Camshaft Cap Bolts
      G03898507Courtesy of FORD MOTOR CO.
  70. Remove the LH and RH camshafts.
    71. CAUTION: The camshaft roller followers must be installed in their original positions.
    NOTE: RH shown, LH similar.
  71. Remove the LH and RH camshaft roller followers.
    • Mark the location of the roller followers, using a permanent-type marker.
      Fig 69: Removing LH And RH Camshaft Roller Followers
      G03898508Courtesy of FORD MOTOR CO.
    72. NOTE: RH shown, LH similar.
  72. Loosen the bolts in the indicated sequence and remove the LH and RH cylinder heads.
    • Discard the bolts and the gaskets.
      Fig 70: Identifying Loosening Sequence Of Cylinder Heads Bolts
      G03898509Courtesy of FORD MOTOR CO.
  73. Support the cylinder head on a bench with the head gasket side up.
    74. NOTE: The straightedge used must be flat within 0.0051 mm (0.0002 in) per foot of tool length.
  74. Inspect all areas of the deck face with a straightedge and feeler gauge. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area, or scratches more than 0.0254 mm (0.001 in).
  75. Remove the bolts and the oil separator cover.
    • Discard the gasket.
      Fig 71: Removing Bolts And Oil Separator Cover
      G03898510Courtesy of FORD MOTOR CO.
  76. Remove the crankshaft key.
    Fig 72: Removing Crankshaft Key
    G03898511Courtesy of FORD MOTOR CO.
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