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Section 330 (Engine - 2.3L - (Except Hybrid)): Disassembly: Engine

WARNING: This page is about a different car, the 2006 Mercury Mariner and 2006 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL(S)

G04618132Courtesy of FORD MOTOR CO.
 Heavy Duty Floor Crane
014-00071 or equivalent
G04618133Courtesy of FORD MOTOR CO.
 Spreader Bar
303-D089 (D93P-6001-A3) or equivalent
G04618134Courtesy of FORD MOTOR CO.
 Engine Stand
014-00232 or equivalent
G04618135Courtesy of FORD MOTOR CO.
 Alignment Plate, Camshaft
303-465 (T94P-6256-CH)
G04618136Courtesy of FORD MOTOR CO.
 Timing Peg, Crankshaft
303-507
G04618137Courtesy of FORD MOTOR CO.
 Holding Fixture, Drive Pinion Flange
205-126 (T78P-4851-A)
G04618138Courtesy of FORD MOTOR CO.
 Adapter for 205-126
(205-072-02)
G04618139Courtesy of FORD MOTOR CO.
 Remover, Oil Seal
303-409 (T92C-6700-CH)
CAUTION:
  1. 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 can occur.
  2. 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.
  3. 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 .

    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: Locating Bolts, Clutch Pressure Plate & Clutch Disc
    G04618140Courtesy of FORD MOTOR CO.
  1. Remove the bolts, clutch pressure plate and clutch disc.
  2. Remove the starter motor isolator.
    Fig 2: Locating Starter Motor Isolator
    G04618141Courtesy of FORD MOTOR CO.
  3. Remove the bolts and the flywheel.
    Fig 3: Locating Bolts & Flywheel
    G04618142Courtesy of FORD MOTOR CO.

    4. Vehicles with automatic transaxle 

  4. Remove the bolts and the flexplate.
    Fig 4: Locating Bolts & Flexplate
    G04618143Courtesy 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: Locating Crankshaft Position (CKP) Sensor Electrical Connector
    G04618144Courtesy of FORD MOTOR CO.
  7. Remove the nut and disconnect the generator electrical connections.
    Fig 6: Locating Nut & Generator Electrical Connections
    G04618145Courtesy of FORD MOTOR CO.
  8. Remove the 2 lower catalytic converter bolts.
    Fig 7: Locating Lower Catalytic Converter Bolts
    G04618146Courtesy of FORD MOTOR CO.
  9. Remove the 6 heat shield bolts and the heat shield.
    Fig 8: Locating Heat Shield Bolts & Heat Shield
    G04618147Courtesy of FORD MOTOR CO.
  10. Remove and discard the 7 exhaust manifold nuts.
    Fig 9: Locating Exhaust Manifold Nuts
    G04618148Courtesy of FORD MOTOR CO.
  11. Remove the catalytic converter and discard the exhaust manifold gasket.
  12. Remove the bolts and the generator.
    Fig 10: Locating Bolts & Generator
    G04618149Courtesy of FORD MOTOR CO.
  13. Loosen the bolt and remove the accessory drive belt idler pulley.
    Fig 11: Locating Accessory Drive Belt Idler Pulley Bolt
    G04618150Courtesy of FORD MOTOR CO.
  14. If equipped, loosen the bolt and remove the accessory drive belt idler pulley.
    Fig 12: Locating Bolt & Accessory Drive Belt Idler Pulley
    G04618151Courtesy of FORD MOTOR CO.
  15. Remove the bolts and the coolant pump pulley.
    Fig 13: Locating Coolant Pump Pulley Bolts
    G03897969Courtesy of FORD MOTOR CO.
  16. Remove the bolts and the coolant pump.
    Fig 14: Locating Coolant Pump Bolts
    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: Locating Engine Vacuum Tube
      G04618154Courtesy of FORD MOTOR CO.
  18. Detach the 2 wiring harness retainers and position the harness aside.
    Fig 16: Locating Wiring Harness Retainers
    G04618155Courtesy of FORD MOTOR CO.
  19. If equipped, disconnect the oil cooler hoses.
    Fig 17: Locating Oil Cooler Hoses
    G04618156Courtesy of FORD MOTOR CO.
  20. Remove the bolts and the thermostat housing assembly.
    Fig 18: Locating Bolts & Thermostat Housing Assembly
    G04618157Courtesy of FORD MOTOR CO.
  21. Remove the bolts and the oil level indicator.
    Fig 19: Locating Bolts & Oil Level Indicator
    G04618158Courtesy of FORD MOTOR CO.
  22. Disconnect the oil pressure sensor electrical connector.
    Fig 20: Locating Oil Pressure Sensor Electrical Connector
    G04618159Courtesy of FORD MOTOR CO.
    23. NOTE: Early build with oil cooler shown, late build without oil cooler similar.
  23. Remove the oil filter, 4 bolts and the oil filter adapter.
    • Discard the oil filter and gasket.
      Fig 21: Locating Oil Filter, Bolts & Oil Filter Adapter
      G04618160Courtesy 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: Locating Bolt & Capacitor
    G04618161Courtesy of FORD MOTOR CO.
  26. Detach the 2 wiring harness retainers.
    Fig 23: Locating Wiring Harness Retainers
    G04618162Courtesy of FORD MOTOR CO.
  27. Disconnect the knock sensor (KS) and detach the 2 wiring harness retainers.
    Fig 24: Locating Knock Sensor (KS) & Wiring Harness Retainers
    G04618163Courtesy of FORD MOTOR CO.
  28. Disconnect the temperature manifold absolute pressure (TMAP) electrical connector.
    Fig 25: Locating Temperature Manifold Absolute Pressure (TMAP) Electrical Connector
    G04618164Courtesy of FORD MOTOR CO.
  29. Disconnect the idle air control (IAC) motor electrical connector.
    Fig 26: Locating Idle Air Control (IAC) Motor Electrical Connector
    G04618165Courtesy of FORD MOTOR CO.
  30. Disconnect the swirl control valve electrical connector.
    Fig 27: Locating Swirl Control Valve Electrical Connector
    G04618166Courtesy of FORD MOTOR CO.
  31. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum tube.
    Fig 28: Locating Fuel Rail Pressure & Temperature Sensor Electrical Connector
    G04618167Courtesy of FORD MOTOR CO.
  32. Disconnect the throttle position (TP) sensor electrical connector.
    Fig 29: Locating Throttle Position (TP) Sensor Electrical Connector
    G04618168Courtesy 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: Locating Intake Manifold Aside & Bolt
    G04618169Courtesy 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: Locating Positive Crankcase Ventilation (PCV) Hose
    G04618170Courtesy of FORD MOTOR CO.
  35. Remove the exhaust gas recirculation (EGR) tube.
    Fig 32: Locating Exhaust Gas Recirculation (EGR) Tube
    G04618171Courtesy of FORD MOTOR CO.
  36. Disconnect the 4 fuel injector electrical connectors. Detach the 2 wiring harness retainers.
    Fig 33: Locating Fuel Injector Electrical Connectors
    G04618172Courtesy of FORD MOTOR CO.
  37. Remove the 2 bolts and the fuel rail with the fuel injectors.
    Fig 34: Locating Bolts & Fuel Rail With Fuel Injectors
    G04618173Courtesy of FORD MOTOR CO.
  38. If equipped, remove the fuel rail spacers.
    Fig 35: Locating Fuel Rail Spacers
    G04618174Courtesy of FORD MOTOR CO.
  39. Detach the wiring harness retainer.
    Fig 36: Locating Wiring Harness Retainer
    G04618175Courtesy of FORD MOTOR CO.
  40. Disconnect the EGR valve and radio interference capacitor electrical connectors. Detach the wiring harness retainer.
    Fig 37: Locating EGR Valve & Radio Interference Capacitor Electrical Connectors
    G04618176Courtesy of FORD MOTOR CO.
  41. Disconnect the coil-on-plug and camshaft position (CMP) sensor electrical connectors.
    Fig 38: Locating Coil-On-Plug & Camshaft Position (CMP) Sensor Electrical Connectors
    G04618177Courtesy of FORD MOTOR CO.
  42. Detach the wiring harness retainer.
    Fig 39: Locating Wiring Harness Retainer
    G04618178Courtesy 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: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector
    G04618179Courtesy of FORD MOTOR CO.
  44. Disconnect the coolant hose.
    Fig 41: Locating Coolant Hose (1 Of 3)
    G04618180Courtesy of FORD MOTOR CO.
  45. Disconnect and remove the coolant hose.
    Fig 42: Locating Coolant Hose (2 Of 3)
    G04618181Courtesy of FORD MOTOR CO.
  46. Disconnect and remove the coolant hoses.
    Fig 43: Locating Coolant Hose (3 Of 3)
    G04618182Courtesy of FORD MOTOR CO.
  47. Remove the bolt and the KS.
    Fig 44: Locating Bolt & KS
    G04618183Courtesy of FORD MOTOR CO.
  48. Remove the bolts and the crankcase vent oil separator.
    Fig 45: Locating Bolts & Crankcase Vent Oil Separator
    G04618184Courtesy of FORD MOTOR CO.
  49. If equipped, remove the block heater.
    Fig 46: Locating Block Heater
    G04618185Courtesy of FORD MOTOR CO.
  50. Remove the crankcase vent tube and the coil-on-plugs.
    Fig 47: Locating Crankcase Vent Tube & Coil-On-Plugs
    G04618186Courtesy of FORD MOTOR CO.
    51. CAUTION: Only use hand tools when removing or installing the spark plugs, damage can occur to the cylinder head or spark plug.
  51. Remove the spark plugs and the CHT sensor.
    • Discard the CHT.
      Fig 48: Locating Spark Plugs & CHT Sensor
      G04618187Courtesy of FORD MOTOR CO.
  52. Remove the bolts and the valve cover.
    Fig 49: Locating Bolts & Valve Cover
    G04618188Courtesy 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.
      Fig 50: Locating Crankshaft Pulley
      G04618189Courtesy of FORD MOTOR CO.
    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 51: Identifying Special Camshaft Tool (303-465)
    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 52: 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. The crankshaft must remain at the TDC position during the disassembly.
    Fig 53: Identifying Special Tool (303-507)
    G04617907Courtesy of FORD MOTOR CO.
  56. Install the special tool.
  57. Assemble the special tools using 4 hardened washers in the locations shown in Fig 54.
    Fig 54: Assembling Special Tools (205-072-02, 205-126)
    G04618193Courtesy of FORD MOTOR CO.
    58. CAUTION:
    1. The crankshaft must remain in the 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).
    2. If the crankshaft sprocket diamond washer comes off with the crankshaft pulley, it must be installed back onto the crankshaft.
  58. 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.
      Fig 55: Identifying Special Tools Assembly (205-072-02/205-126) And Crankshaft Pulley Bolt
      G04618194Courtesy of FORD MOTOR CO.
    59. CAUTION: Use care not to damage the engine front cover or the crankshaft when removing the seal.
    Fig 56: Removing Crankshaft Front Oil Seal Using Special Tool (303-409)
    G04618195Courtesy 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 57: Locating CKP Sensor
    G03898012Courtesy of FORD MOTOR CO.
  60. Remove and discard the CKP sensor.
  61. Remove the bolts and the engine front cover.
    Fig 58: Locating 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 59: Locating Timing Chain Tensioner Bolt
      G04618198Courtesy of FORD MOTOR CO.
  63. Remove the RH timing chain guide.
    Fig 60: Locating RH Timing Chain Guide
    G03897778Courtesy of FORD MOTOR CO.
  64. Remove the timing chain.
    Fig 61: View Of Timing Chain
    G03897779Courtesy of FORD MOTOR CO.
  65. Remove the bolts and the LH timing chain guide.
    Fig 62: Identifying Bolts And LH Timing Chain Guide
    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 63: 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 64: Identifying Tensioner & Shoulder Bolt
      G04618203Courtesy of FORD MOTOR CO.
    68. NOTE:
    1. Remove the crankshaft sprocket diamond washers located in front of and behind the crankshaft sprocket.
    2. 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 65: Identifying Chain & Sprockets
      G04618204Courtesy of FORD MOTOR CO.
  69. Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.
    Fig 66: Locating Camshaft Lobe
    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 in Fig 67, one turn at a time. Repeat until all the tension is released.
    • Remove the camshaft bearing caps.
    • Remove the camshafts.
      Fig 67: Identifying Loosening/Tightening 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 68: Locating Cylinder Head Bolts
      G04618207Courtesy of FORD MOTOR CO.
  72. Remove the cylinder head alignment dowels.
    Fig 69: Identifying Cylinder Head Alignment Dowels
    G03898024Courtesy of FORD MOTOR CO.
  73. Remove the bolts and the oil pan.
    Fig 70: Locating Bolts & Oil Pan
    G04618209Courtesy of FORD MOTOR CO.
  74. Remove the bolts and the rear crankshaft seal.
    Fig 71: Locating Bolts & Rear Crankshaft Seal
    G04618210Courtesy of FORD MOTOR CO.
  75. Remove the bolts, oil pump pickup tube and gasket.
    Fig 72: Locating Bolts, Oil Pump Pickup Tube & Gasket
    G04618211Courtesy of FORD MOTOR CO.
  76. Remove the bolts and the oil pump.
    Fig 73: Locating Bolts & Oil Pump
    G04618212Courtesy of FORD MOTOR CO.
  77. If necessary, remove the bolts and halfshaft support bracket.
    Fig 74: Locating Bolts & Halfshaft Support Bracket
    G04618213Courtesy of FORD MOTOR CO.
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