Engine - 2.5L DURATEC (125KW/170PS): Disassembly: Engine

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Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	205-153 (T80T-4000-W) Handle
Courtesy of FORD MOTOR COMPANY	303-1247 VCT Spark Plug Tube Seal Remover and Installer TKIT-2006UF-FLM TKIT-2006UF-ROW
Courtesy of FORD MOTOR COMPANY	303-1416 Tool, Crank Damper Holding TKIT-2008ET-FLM
Courtesy of FORD MOTOR COMPANY	303-409 (T92C-6700-CH) Remover, Crankshaft Seal TKIT-1992-FH/FMH/FLMH TKIT-1993-LMH/MH
Courtesy of FORD MOTOR COMPANY	303-465 Tool, Camshaft Align Timing TKIT-1994-LMH/MH2 TKIT-1994-FH/FMH/FLMH
Courtesy of FORD MOTOR COMPANY	303-507 Timing Peg, Crankshaft TDC TKIT-2001N-FLM TKIT-2001N-ROW

1. Loosen the fasteners and remove the valve cover.

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2. Using the special tools, remove the VCT oil control solenoid seals. Use Special Service Tool: 303-1247 VCT Spark Plug Tube Seal Remover and Installer., 205-153 (T80T-4000-W) Handle.

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3. Remove the bolts and the CKP sensor.

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4. Remove the engine plug bolt.

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5. NOTE: Failure to position the No. 1 piston at TDC can result in damage to the engine. Turn the engine in the normal direction of rotation only.

   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.

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6. NOTE: Only rotate the crankshaft clockwise.
   1. Install the special tool. Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.
   2. Rotate the crankshaft slowly until the crankshaft stops.

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7. NOTE: The Camshaft Alignment Plate 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 Plate cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.

   Install the special tool. Install Special Service Tool: 303-465 Tool, Camshaft Align Timing.

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8. 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 Crankshaft Damper Holding Tool and the bolt should be removed using an air impact wrench (1/2-in drive minimum).
   NOTE: If equipped, the crankshaft sprocket diamond washer may come off with the crankshaft pulley.
   • Using the special tool, remove the bolt and the crankshaft pulley. Use Special Service Tool: 303-1416 Tool, Crank Damper Holding.
   • Discard the bolt and washer.

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9. NOTE: Early build engines are equipped with a diamond washer on each side of the crankshaft sprocket. Late build engines have a laser etched crankshaft sprocket and do NOT require diamond washers. If an early build engine requires crankshaft sprocket replacement, discard the diamond washers and the sprocket and install a new laser etched sprocket (service part). Diamond washers should NEVER be installed with the laser etched sprocket.

   If equipped, remove the diamond washer.

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

    Using the special tool, remove the crankshaft front seal and discard. Use Special Service Tool: 303-409 (T92C-6700-CH) Remover, Crankshaft Seal.

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11. Remove the bolts and the coolant pump. Discard the O-ring seal.

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12. Remove the bolts and the engine front cover.

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13. NOTE: If equipped with cast iron timing chain tensioner.
    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.

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14. NOTE: If it is necessary to install a new timing chain tensioner, a cast iron tensioner is to be replaced with an aluminum tensioner (6K254). The existing bolts must be discarded and replaced with new bolts (6K282).
    NOTE: If equipped with cast iron timing chain tensioner.

    Remove the bolts and the timing chain tensioner.

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15. NOTE: If equipped with aluminum timing chain tensioner.

    Remove the bolts and the timing chain tensioner.

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16. Remove the bolts, timing chain guide and tensioner arm.

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17. Remove the timing chain.

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18. NOTE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
    NOTE: Use the flats on the camshaft to prevent camshaft rotation.

    Remove the bolts and the camshaft sprockets.

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19. 1. Release the tension on the tensioner spring.
    2. Remove the shoulder bolts and the tensioner.

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20. • Remove the bolt and oil pump sprocket.
    • Remove the timing chain.

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21. Remove the crankshaft sprocket.

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22. NOTE: Early build engines are equipped with a diamond washer on each side of the crankshaft sprocket. Late build engines have a laser etched crankshaft sprocket and do NOT require diamond washers. If an early build engine requires crankshaft sprocket replacement, discard the diamond washers and the sprocket and install a new laser etched sprocket (service part). Diamond washers should NEVER be installed with the laser etched sprocket.

    If equipped, remove the diamond washer.

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23. Remove the bolt and the VCT oil control solenoid.

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24. NOTE: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.
    NOTE: Mark the location and orientation of each camshaft bearing cap.
    NOTE: Mark the location of the camshafts prior to removal.

    Loosen the camshaft bearing caps in sequence 2 turns at a time until all tension is released from the camshaft bearing caps and remove the camshaft bearing caps and camshafts. Remove Special Service Tool: 303-465 Tool, Camshaft Align Timing.

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25. 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.
    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.

    Remove the valve tappets.

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26. Inspect the valve tappets. Install new parts as necessary.

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27. • Remove the bolts and the cylinder head.
    • Discard the bolts.

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28. Check the cylinder head distortion. Refer to: Cylinder Head Distortion .
29. Remove and discard the cylinder head gasket.

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30. Remove the dowels.

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31. Check the cylinder block distortion. Refer to: Cylinder Block Distortion .
32. Remove the bolts and the oil pan.

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33. • Remove the bolts and the oil pickup tube.
    • Discard the O-ring seal.

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34. Remove the bolts and the crankshaft rear seal. Discard the crankshaft rear seal.

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35. Remove the bolts and the oil pump.

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36. Make sure the crankshaft TDC timing peg is still installed and the engine is still at TDC. Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the crankshaft TDC timing peg. Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.

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37. NOTE: Note the position of the components before removal.

    Index-mark the balance shaft assembly.

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38. Remove the bolts and the balance shaft assembly.

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39. Remove the special tool. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.

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40. 1. Visual check.
    2. NOTE: Remove the carbon buildup, do not scratch the cylinder wall. Remove all debris from the cylinder.

       Clean the specified component with the specified material.

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41. NOTE: Clearly mark the connecting rods, connecting rod caps and connecting rod bearings in numerical order for correct orientation for reassembly.

    Remove the bolts and the connecting rod caps.

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42. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

    Remove the pistons.

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

    Remove the connecting rod bearings.

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44. • Remove the bolts in sequence shown.
    • Remove the main bearing beam.
    Fig 1: Main Bearing Beam Loosening Sequence

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45. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.

    Remove the lower main bearing beam bearings.

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46. Remove the crankshaft.

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47. 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.

    Remove the upper crankshaft main bearings.

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48. NOTE: If the oil squirters are being reused, mark them in order for correct location during reassembly.

    Remove the oil squirters.

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49. Inspect the piston. Refer to: Piston Inspection .
50. Inspect the cylinder bore taper. Refer to: Cylinder Bore Taper .