Section 3 (Engine Mechanical - 2.0L ECOBOOST): Disassembly: Engine

WARNING: This page is about a different car, the 2013 Ford Focus. However, it is still accessible from the selected car via links, so may be relevant.

SPECIAL TOOL(S) / GENERAL EQUIPMENT

	205-153 Handle
	300-OTC1819E 2, 200# Floor Crane, Fold Away
	303-103 Holding Tool, Flywheel TKIT-2009TC-F
	303-1247/1 Remover, VCT Spark Plug Tube Seal
	303-1565 Alignment Tool, Camshaft
	303-409 Remover, Crankshaft Seal TKIT-1992-FH/FMH/FLMH TKIT-1993-LMH/MH
	303-507 Timing Peg, Crankshaft TDC TKIT-2001N-FLM
	307-005 Slide Hammer
	310-206 Remover, Fuel Injector TKIT-2009A-FLM
Strap Wrench

MATERIALS SPECIFICATIONS

Name	Specification
Motorcraft® Metal Surface Prep ZC-31-A	-

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, otherwise severe engine damage can 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.

Loosen each bolt 2 turns at a time until all bolts are removed.

Fig 1: Identifying Clutch Bolts Loosening Sequence
Courtesy of FORD MOTOR CO.
Discard the specified component. Follow local disposal regulations.
Special Tool(s) : 303-103 (Holding Tool, Flywheel)

Fig 2: Locating Flywheel Holding Tool And Flexplate Bolts
Courtesy of FORD MOTOR CO.
Install.

Fig 3: Installing Engine On Engine Stand
Courtesy of FORD MOTOR CO.
Remove the Special Tool(s) : 300-OTC1819E (2, 200# Floor Crane, Fold Away)

Fig 4: Removing Floor Crane And Spreader Bar On Engine
Courtesy of FORD MOTOR CO.
Loosen.

Fig 5: Locating Turbocharger Inlet Tube Clamp
Courtesy of FORD MOTOR CO.
Fig 6: Locating Intake Manifold Hose Bracket Bolt And Stud
Courtesy of FORD MOTOR CO.
Fig 7: Locating CKP Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Fig 8: Locating Wiring Harness Retainers On Engine Front Cover
Courtesy of FORD MOTOR CO.
Discard the specified component. Follow local disposal regulations.

Fig 9: Locating Turbocharger Coolant Tube Banjo Bolts And Turbocharger Coolant Tube Clamps
Courtesy of FORD MOTOR CO.
Fig 10: Locating Electrical Connector And Turbocharger Control Vacuum Hoses Clamps
Courtesy of FORD MOTOR CO.
Discard the specified component. Follow local disposal regulations.

Fig 11: Locating Turbocharger Oil Supply Tube/Gaskets And Turbocharger Oil Supply Tube Banjo Bolts
Courtesy of FORD MOTOR CO.
Discard the specified component. Follow local disposal regulations.

Fig 12: Locating Turbocharger Oil Filter
Courtesy of FORD MOTOR CO.
Discard the specified component. Follow local disposal regulations.

Fig 13: Locating Bolts And Turbocharger Oil Return Tube
Courtesy of FORD MOTOR CO.
Fig 14: Locating Bolts And Turbocharger Heat Shield
Courtesy of FORD MOTOR CO.
Discard the specified component. Follow local disposal regulations.

Fig 15: Locating Nuts And Turbocharger
Courtesy of FORD MOTOR CO.
Discard the specified component. Follow local disposal regulations.

Fig 16: Locating Turbocharger Gasket And Turbocharger-To-Cylinder Head Studs
Courtesy of FORD MOTOR CO.
Fig 17: Locating CHT Sensor Electrical Connector, Wiring Harness Retainer And ECT Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Fig 18: Locating Bolts And Halfshaft Bracket
Courtesy of FORD MOTOR CO.
Loosen.

Fig 19: Locating Coolant Pump Pulley Bolts
Courtesy of FORD MOTOR CO.
Refer to: AIR CONDITIONING (A/C) COMPRESSOR BELT .
Fig 20: Rotating Pulley
Courtesy of FORD MOTOR CO.
Fig 21: Identifying Hose Clamp
Courtesy of FORD MOTOR CO.
Fig 22: Locating A/C Compressor, Bolts, Connector And Tube Retainer
Courtesy of FORD MOTOR CO.
Fig 23: Locating Generator Cap
Courtesy of FORD MOTOR CO.
Fig 24: Locating Generator Nut, Wire Terminal And Wire Harness Electrical Connector
Courtesy of FORD MOTOR CO.
Fig 25: Locating Coolant Pump Pulley Bolts, Power Steering Pump Bracket Bolts And Generator Bolts
Courtesy of FORD MOTOR CO.
Fig 26: Locating Coolant Pump Bolts And Idler Pulley Bracket Bolt, Nut
Courtesy of FORD MOTOR CO.
Fig 27: Locating Coolant Hoses Clamps
Courtesy of FORD MOTOR CO.

NOTE: A new oil cooler must be installed or severe damage to the engine can occur.

Fig 28: Locating Oil Cooler Bolt

Courtesy of FORD MOTOR CO.

Discard the specified component. Follow local disposal regulations.
Discard the specified component. Follow local disposal regulations.

Fig 29: Locating Oil Filter Adapter Bolts And EOP Switch Electrical Connector
Courtesy of FORD MOTOR CO.
1. Refer to: QUICK RELEASE COUPLING .
Fig 30: Locating Hose Retainers
Courtesy of FORD MOTOR CO.
Fig 31: Locating Tube Retainers
Courtesy of FORD MOTOR CO.
Fig 32: Identifying Connector And Bolts
Courtesy of FORD MOTOR CO.
Fig 33: Locating MAP Sensor, FRP Sensor And Fuel Charge Harness Electrical Connectors
Courtesy of FORD MOTOR CO.
Fig 34: Identifying Intake Manifold Bolts Loosing Sequence
Courtesy of FORD MOTOR CO.
Fig 35: Identifying Connector Bolts
Courtesy of FORD MOTOR CO.
Fig 36: Locating KS Electrical Connectors, KS Bolts And Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
Fig 37: Locating Crankcase Vent Oil Separator Bolts And Coolant Bypass Hose Clamps
Courtesy of FORD MOTOR CO.
Fig 38: Locating Fuel Injector Electrical Connectors And Fuel Charge Wiring Harness
Courtesy of FORD MOTOR CO.
Fig 39: Locating Pin-Type Retainers And Fuel Rail Insulator
Courtesy of FORD MOTOR CO.

NOTE: To release the fuel pressure in the high pressure fuel tube, wrap the fuel injection pump flare nut with a shop towel to absorb any residual fuel during the loosening of the fuel injection pump flare nut.

Fig 40: Locating High Pressure Fuel Tube Flare Nuts And High Pressure Fuel Tube Bolts

Courtesy of FORD MOTOR CO.

Discard the specified component. Follow local disposal regulations.

NOTE: Pull out the fuel rails in the direction of the fuel injector axis or damage may occur to the fuel injectors.

NOTE: Use compressed air and remove any dirt or foreign material from the cylinder head, block and general surrounding area of the fuel rail and injectors.

NOTE: When removing the fuel rails, the fuel injectors may remain in the fuel rails but normally remain in the cylinder head and require the use of a Fuel Injector Remover tool to extract.

Fig 41: Locating Fuel Rail Bolts

Courtesy of FORD MOTOR CO.

Discard the specified component. Follow local disposal regulations.
Remove any of the fuel injectors that remained in the fuel rail.

Fig 42: Locating Fuel Injectors
Courtesy of FORD MOTOR CO.
Remove any of the fuel injectors that remained in the fuel rail.
Special Tool(s) : 307-005 (Slide Hammer) , 310-206 (Remover, Fuel Injector)

Fig 43: Removing Fuel Injectors In Fuel Rail
Courtesy of FORD MOTOR CO.
Discard the specified component. Follow local disposal regulations.

Fig 44: Identifying Fuel Injector Clips
Courtesy of FORD MOTOR CO.
Discard the specified component. Follow local disposal regulations.

Fig 45: Locating Upper Fuel Injector O-Ring Seals And Upper Fuel Injector O-Ring Seal Support Rings
Courtesy of FORD MOTOR CO.
NOTE: Do not attempt to cut the lower Teflon® seal without first pulling it away from the fuel injector or damage to the injector may occur.

NOTE: Be very careful when removing the lower Teflon® seals, not to scratch, nick or gouge the fuel injectors.
1. Pull the lower Teflon® seal away from the injector. Long-nosed pliers.
2. Carefully cut and discard the lower fuel injector Teflon® seals. Cutting knife.
3. Discard the specified component. Follow local disposal regulations.
Fig 46: Cutting Lower Fuel Injector Teflon® Seals
Courtesy of FORD MOTOR CO.
Fig 47: Locating Thermostat Housing Bolts
Courtesy of FORD MOTOR CO.
Fig 48: Identifying Brake Vacuum Pump
Courtesy of FORD MOTOR CO.
Fig 49: Locating Brake Vacuum Pump Bolts
Courtesy of FORD MOTOR CO.
Fig 50: Locating Bolts And Fuel Injection Pump Bracket
Courtesy of FORD MOTOR CO.
Fig 51: Locating Fuel Injection Pump Bolts
Courtesy of FORD MOTOR CO.
Discard the specified component. Follow local disposal regulations.

Fig 52: Locating Fuel Injection Pump O-Ring Seal
Courtesy of FORD MOTOR CO.
Fig 53: Sliding Fuel Injection Pump Tappet Out Of Fuel Injection Pump Housing
Courtesy of FORD MOTOR CO.

NOTE: The fuel injection cam lobe must be positioned at zero lift before removing the fuel injection pump housing.

Fig 54: Rotating Engine Clockwise Until Fuel Injection Cam Lobe Is At Zero Lift Using Crankshaft Pulley Bolt

Courtesy of FORD MOTOR CO.

Turn the component clockwise.
Fig 55: Locating Stud Bolts And Fuel Injection Pump Housing
Courtesy of FORD MOTOR CO.
Fig 56: Locating Wiring Harness Electrical Connectors And Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
Fig 57: Locating Bolts And Coil-On-Plugs
Courtesy of FORD MOTOR CO.
1. Early build vehicles equipped with metal vacuum tubes.
2. Late build vehicles equipped with nylon vacuum tubes.
Fig 58: Locating Nylon Vacuum Tubes Retainers And Metal Vacuum Tubes Retainers
Courtesy of FORD MOTOR CO.
Fig 59: Locating Valves Cover Bolts
Courtesy of FORD MOTOR CO.
Discard the specified component. Follow local disposal regulations.

Fig 60: Applying Sealant On Valves Cover
Courtesy of FORD MOTOR CO.

NOTE: The VCT solenoid seals should only be replaced if they are damaged upon inspection.

Fig 61: Removing VCT Solenoid Seals Using VCT Spark Plug Tube Seal Remover And Handle

Courtesy of FORD MOTOR CO.

Visual check. Discard the specified component. Follow local disposal regulations.
Special Tool(s) : 303-1247/1 (Remover, VCT Spark Plug Tube Seal) , 205-153 (Handle)

NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths.

Fig 62: Cleaning Valve Cover

Courtesy of FORD MOTOR CO.

Clean the specified component with the specified material.
Material : Motorcraft® Metal Surface Prep / ZC-31-A
Fig 63: Locating Rear Intake Camshaft Cap And Bolts
Courtesy of FORD MOTOR CO.
Fig 64: Identifying Brake Vacuum Pump Adapter
Courtesy of FORD MOTOR CO.
Turn the crankshaft clockwise until the No. 1 piston is 45 degrees BTDC using the guide holes on the engine front cover and the crankshaft pulley.

Fig 65: Turning Crankshaft Clockwise Until No. 1 Piston Is 45 Degrees BTDC Using Guide Holes On Engine Front Cover And Crankshaft Pulley
Courtesy of FORD MOTOR CO.
Fig 66: Locating Engine Plug Bolt
Courtesy of FORD MOTOR CO.
Install the Special Tool(s) : 303-507 (Timing Peg, Crankshaft TDC)

Fig 67: Identifying Crankshaft TDC Timing Peg
Courtesy of FORD MOTOR CO.

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 engine front cover is removed from graphic for clarity.

Fig 68: Rotating Crankshaft Clockwise Until Crankshaft Contacts Crankshaft TDC Timing Peg

Courtesy of FORD MOTOR CO.

Special Tool(s) : 303-507 (Timing Peg, Crankshaft TDC)

NOTE: The Camshaft Alignment Tool 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 Tool cannot be installed, remove the TDC Timing Peg and rotate the crankshaft three-fourths of a revolution clockwise and repeat the previous 2 steps of this procedure.

Fig 69: Installing Camshaft Alignment Tool Into Rear Of Both Of Camshaft Slots

Courtesy of FORD MOTOR CO.

Tighten the retainer.
Install the Special Tool(s) : 303-1565 (Alignment Tool, Camshaft)

NOTE: 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 Strap Wrench 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.

Fig 70: Locating Crankshaft Bolt

Courtesy of FORD MOTOR CO.

Discard the specified component. Follow local disposal regulations.
General Equipment : Strap Wrench

NOTE: If the diamond washer did not come off with the crankshaft pulley, remove the washer from the crankshaft and discard.

Fig 71: Locating Diamond Washer In Crankshaft

Courtesy of FORD MOTOR CO.

Discard the specified component. Follow local disposal regulations.

NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal.

Fig 72: Removing Crankshaft Front Oil Seal Using Oil Seal Remover

Courtesy of FORD MOTOR CO.

Discard the specified component. Follow local disposal regulations.
Special Tool(s) : 303-409 (Remover, Crankshaft Seal)
Fig 73: Locating CKP Sensor Bolts
Courtesy of FORD MOTOR CO.
Fig 74: Locating Engine Front Cover Bolts
Courtesy of FORD MOTOR CO.
Loosen.

Fig 75: Loosening Exhaust Camshaft Phaser And Sprocket Bolt Using Wrench On Flats Of Exhaust Camshaft To Prevent Camshaft Rotation
Courtesy of FORD MOTOR CO.
Loosen.

Fig 76: Loosening Intake Camshaft Phaser And Sprocket Bolt Using Wrench On Flats Of Intake Camshaft To Prevent Camshaft Rotation
Courtesy of FORD MOTOR CO.
1. Using a small pick, release and hold the ratchet mechanism.
2. While holding the ratchet mechanism in the released position, compress the tensioner by pushing the timing chain arm toward the tensioner.
3. Insert a holding pin into the hole to retain the tensioner.
Fig 77: Compressing Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
Fig 78: Locating Timing Chain Tensioner Bolts
Courtesy of FORD MOTOR CO.
Fig 79: Locating Timing Chain Tensioner Arm And Bolts
Courtesy of FORD MOTOR CO.
Discard the specified component. Follow local disposal regulations.

Fig 80: Locating Bolts Of Intake And Exhaust Camshaft Phaser And Sprockets
Courtesy of FORD MOTOR CO.
Discard the specified component. Follow local disposal regulations.

Fig 81: Identifying Camshaft Phaser And Sprocket Washers
Courtesy of FORD MOTOR CO.
Remove the Special Tool(s) : 303-1565 (Alignment Tool, Camshaft)

Fig 82: Installing Camshaft Alignment Tool Into Rear Of Both Of Camshaft Slots
Courtesy of FORD MOTOR CO.
Fig 83: Locating Bolts And Variable Camshaft Timing Solenoids
Courtesy of FORD MOTOR CO.
Fig 84: Locating Bolts And Front Camshaft Bearing Cap
Courtesy of FORD MOTOR CO.

NOTE: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.

NOTE: Note the location and orientation of each camshaft bearing cap and the position of the camshaft lobes on the No. 1 cylinder for installation reference.

Fig 85: Identifying Camshaft Bearing Caps Bolts Loosening Sequence

Courtesy of FORD MOTOR CO.

Loosen the camshaft bearing caps in sequence 2 turns at a time until all tension is released from the camshaft bearing caps.
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.

Fig 86: Identifying Valve Tappets Location
Courtesy of FORD MOTOR CO.

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.

Fig 87: Inspecting Valve Tappet

Courtesy of FORD MOTOR CO.

Visual check.
Discard the specified component. Follow local disposal regulations.

Fig 88: Locating Cylinder Head Bolts
Courtesy of FORD MOTOR CO.
Discard the specified component. Follow local disposal regulations.

Fig 89: Identifying Head Gasket
Courtesy of FORD MOTOR CO.
Fig 90: Locating Cylinder Head Alignment Dowels
Courtesy of FORD MOTOR CO.

NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.

NOTE: Observe all warnings or cautions and follow all application directions contained on the packaging of the metal surface prep.

NOTE: Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.

Fig 91: Cleaning Head Gasket And Cylinder Head Using Plastic Scraping Tool

Courtesy of FORD MOTOR CO.

Clean the specified component with the specified material.
Material : Motorcraft® Metal Surface Prep / ZC-31-A
- Refer to: CYLINDER BLOCK DISTORTION .
- Refer to: CYLINDER HEAD DISTORTION .
Fig 92: Locating Oil Pan Bolts
Courtesy of FORD MOTOR CO.

NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove traces of sealant.

Fig 93: Removing Traces Of Sealant From Oil Pan Using Plastic Scraping Tool

Courtesy of FORD MOTOR CO.

Plastic scraper.
Discard the specified component. Follow local disposal regulations.

Fig 94: Locating Crankshaft Rear Seal Retainer Plate Bolts
Courtesy of FORD MOTOR CO.
Discard the specified component. Follow local disposal regulations.

Fig 95: Locating Bolts And Oil Pump Screen And Pickup Tube
Courtesy of FORD MOTOR CO.
Fig 96: Locating Tensioner Spring And Shoulder Bolt
Courtesy of FORD MOTOR CO.
Fig 97: Locating Crankshaft Sprocket
Courtesy of FORD MOTOR CO.
Discard the specified component. Follow local disposal regulations.

Fig 98: Locating Diamond Washer
Courtesy of FORD MOTOR CO.
Fig 99: Locating Oil Pump Sprocket Bolt
Courtesy of FORD MOTOR CO.
Fig 100: Locating Oil Pump Bolts
Courtesy of FORD MOTOR CO.
Clean the specified component with the specified material.
Material : Motorcraft® Metal Surface Prep / ZC-31-A

Fig 101: Cleaning Oil Pump And Cylinder Block Mating Surfaces With Metal Surface Prep
Courtesy of FORD MOTOR CO.

NOTE: Make sure the Crankshaft TDC Timing Peg is still installed and the engine is still at TDC.

Fig 102: Locating Crankshaft TDC Timing Peg

Courtesy of FORD MOTOR CO.

Visual check.

NOTE: Mark the balance shaft assembly front shafts on the top for reference that the balance shaft assembly is at TDC.

Fig 103: Marking Balance Shaft Assembly Front Shafts On Top For Reference That Balance Shaft Assembly Is At TDC

Courtesy of FORD MOTOR CO.

Marker.
NOTE: Due to the precision interior construction of the balance shaft assembly, it should not be disassembled.

Fig 104: Locating Balancer Unit Bolts
Courtesy of FORD MOTOR CO.
Remove the Special Tool(s) : 303-507 (Timing Peg, Crankshaft TDC)

Fig 105: Identifying Crankshaft TDC Timing Peg
Courtesy of FORD MOTOR CO.
1. Visual check.
2. Abrasive pad.
Fig 106: Cleaning Cylinder Block Surface
Courtesy of FORD MOTOR CO.
NOTE: Clearly mark the connecting rods, connecting rod caps and connecting rod bearings in numerical order for correct orientation for reassembly.

Fig 107: Locating Connecting Rod Caps Bolts
Courtesy of FORD MOTOR CO.
NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

Fig 108: Removing Piston And Rod Assemblies From Engine Block
Courtesy of FORD MOTOR CO.

NOTE: Mark the position of the parts, so they can be installed in their original positions.

Fig 109: Removing Connecting Rod Big End Bearing

Courtesy of FORD MOTOR CO.

Refer to: PISTON INSPECTION .
Remove in the sequence shown in illustration.

Fig 110: Identifying Main Bearing Beam Bolts Removing Sequence
Courtesy of FORD MOTOR CO.
NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.

Fig 111: Identifying Main Bearings Correct Orientation
Courtesy of FORD MOTOR CO.
Fig 112: Identifying Crankshaft In Engine Block
Courtesy of FORD MOTOR CO.
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.

Fig 113: Identifying Main Bearings Correct Orientation
Courtesy of FORD MOTOR CO.
Fig 114: Locating Bolts And Engine Piston Oil Coolers
Courtesy of FORD MOTOR CO.