Section 53 (Engine - 1.0L ECOBOOST (92KW/125PS)): Disassembly: Engine

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Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	303-1602Locking Tool, Crankshaft
Courtesy of FORD MOTOR COMPANY	303-1611Torque Multiplier
Courtesy of FORD MOTOR COMPANY	303-1611-01Adapter for 303-1611
Courtesy of FORD MOTOR COMPANY	303-1611-02Adapter for 303-1611, Torque MultiplierTKIT-2014A-FLTKIT-2014A-ROW
Courtesy of FORD MOTOR COMPANY	303-409 (T92C-6700-CH)Remover, Crankshaft SealTKIT-1992-FH/FMH/FLMHTKIT-1993-LMH/MH
Courtesy of FORD MOTOR COMPANY	307-005 (T59L-100-B)Slide Hammer
Courtesy of FORD MOTOR COMPANY	310-206Remover, Fuel InjectorTKIT-2009A-FLM
Lifting Bracket
Floor Crane
Mounting Stand
Polydrive Bit Socket
Hot Air Gun
Hose Clamp Remover/Installer
4 mm Drill Bit

1. Install engine on the mounting stand. Use the General Equipment: Mounting Stand

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2. Remove the General Equipment: Lifting BracketRemove the General Equipment: Floor Crane

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3. 1. Disconnect the EVAP canister purge valve electrical connector.
   2. Disconnect the quick release coupling. Refer to: Quick Release Coupling .
   3. Detach the retainers and remove the EVAP canister purge valve.

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4. 1. Disconnect the engine wiring harness electrical connectors.
   2. Detach the engine wiring harness retainers.

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5. Detach the wiring harness retainers.

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6. 1. Position the protective cover aside.
   2. Remove the generator nut.

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7. 1. Disconnect the generator wiring harness terminal.
   2. Disconnect the engine wiring harness electrical connector.
   3. Detach the engine wiring harness retainers.

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8. 1. Disconnect the engine wiring harness electrical connector.
   2. Detach the engine wiring harness retainers.

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9. 1. Disconnect the oil control solenoid electrical connector.
   2. Detach the wiring harness retainer.

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10. 1. Disconnect the oil pressure switch, the KS.
    2. Detach the wiring harness retainers.

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11. Detach the engine wiring harness retainers and remove the wiring harness from the engine.

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12. 1. Remove the nuts.
    2. Disconnect the vacuum hoses. Use the General Equipment: Hose Clamp Remover/Installer
    3. Detach the vacuum hose retainers and remove the vacuum hose assembly from the engine.

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13. Remove the bolts and the engine lifting bracket.

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14. Remove the bolts and the coolant pump pulley.

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15. WARNING: Take extra care when handling the compressed spring.

    Remove the bolts and the accessory drive belt tensioner. Use the General Equipment: 4 mm Drill Bit

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16. Remove the bolts and the generator.

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17. Remove the bolt and the accessory drive belt idler pulley.

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18. 1. NOTE: Brackets may vary, typical bracket shown.

       Remove the bolts, the bracket and the coolant pump.

    2. Discard the indicated bolts.

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19. 1. Disconnect the coolant hose. Use the General Equipment: Hose Clamp Remover/Installer
    2. Detach the coolant hose from the retainers.
    3. Remove the bolts and the coolant hose assembly.

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20. Remove the fasteners and the bracket.

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21. 1. Remove the bolts.
    2. Release the clamp and remove the coolant hose assembly. Use the General Equipment: Hose Clamp Remover/Installer

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22. NOTE: Inspect the O-ring seal on the turbocharger drain tube. Replace the turbocharger drain tube, if necessary.
    1. Remove the retainers and the turbocharger oil drain tube.
    2. Remove and discard the gasket.

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23. 1. Remove the TC oil supply tube banjo bolt.
    2. Remove the TC oil supply tube bracket bolt.
    3. Remove the nuts and the TC assembly.
    4. Remove the bolt and discard the TC oil supply tube (includes banjo bolt).

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24. 1. Remove the bolt and the heat shield.
    2. Discard the heat shield.

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25. Remove and discard the studs.

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26. Remove the stud bolts and the vacuum pump.

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27. Remove and discard the high pressure fuel tube.

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28. 1. Loosen each bolt one turn at a time until all bolts are removed.
    2. Discard the bolts.
    3. Remove the high pressure fuel pump.

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29. Remove the high-pressure fuel pump tappet.

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30. Inspect the high-pressure fuel pump tappet. If any flat spots or scoring are found, especially in the indicated areas, then inspect the high-pressure fuel pump and the fuel pump tappet drive lobe. Install new components as needed.

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31. Remove the bolts and the ignition coil-on-plugs.

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32. 1. Remove the retainers and the CMP sensors.
    2. Detach the retainers, disconnect the fuel injector electrical connectors and remove the wire harness.

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33. NOTE: Pull out the fuel rails in the direction of the fuel injector axis or damage may occur to the fuel injectors.
    NOTE: Use regulated low pressure compressed air to remove any dirt or foreign material from the cylinder head, block and general surrounding area of the fuel rail and the fuel injectors.
    NOTE: When removing the fuel rails, the fuel injectors may remain in the cylinder head and require the use of a Fuel Injector Remover tool to extract.

    Remove the bolts and the fuel rail.

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34. NOTE: Take extra care when handling the components.
    NOTE: Make sure that the component is clean, free of foreign material and lubricant.
    NOTE: Only use moderate force.

    Remove any of the fuel injectors that remained in the fuel rail.

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35. NOTE: Take extra care when handling the components

    Remove and discard the fuel injector clip.

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36. NOTE: This step is only necessary if the component remains in the cylinder head.

    Remove and discard the fuel injector clips.

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37. NOTE: Use minimal force to remove the fuel injectors that remained in the cylinder head with the fuel injector remover tool or damage to the fuel injector assembly may occur. Wiggling the injector by hand to break it loose may allow the injector to be removed by hand.
    NOTE: This step is only necessary if the component remains in the cylinder head.

    Using the special tools, remove any of the fuel injectors that remained in the cylinder head.

    • Use Special Service Tool: 307-005 (T59L-100-B) Slide Hammer.
    • Use Special Service Tool: 310-206 Remover, Fuel Injector.

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38. NOTE: Take extra care when handling the components
    NOTE: Make sure that the component is clean, free of foreign material and lubricant.

    Remove and discard the fuel injector seal, washer and O-ring seal.

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39. Remove the crankcase vent tube.

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40. NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

    Remove the bolts, studs and the intake manifold.

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41. NOTE: A new oil cooler must be installed or severe damage to the engine occur.
    1. Remove the bolt and the oil cooler.
    2. Discard the oil cooler.

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42. 1. Remove the retainer and the oil pump control solenoid.
    2. NOTE: Note the position of the component before removal.

       Remove the bolts and the KS.

    3. Remove and discard the oil pressure switch.

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43. Remove the bolts and the VCT solenoids.

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44. Remove the oil level indicator.

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45. Remove the studs, bolts and the valve cover.

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46. Inspect the valve cover gasket, replace if necessary.

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47. If equipped, remove the retainer and the shield.

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48. NOTE: Flywheel shown, flexplate similar

    Install Special Service Tool: 303-1602 Locking Tool, Crankshaft.

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49. 1. M8x30
    2. M8x25 Install Special Service Tool: 303-1611-02 Adapter for 303-1611, Torque Multiplier.

       Torque 18 lb.ft (24 Nm)

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50. Install Special Service Tool: 303-1611-01 Adapter for 303-1611.

    Torque 18 lb.ft (24 Nm)

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51. NOTE: Only tighten the nut finger tight at this stage.

    Install Special Service Tool: 303-1611 Torque Multiplier.

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52. Loosen: 5 turn(s)

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53. Remove Special Service Tool: 303-1611 Torque Multiplier.

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54. 1. Remove the crankshaft bolt.
    2. Remove the crankshaft pulley.
    3. NOTE: The production engine is not equipped with a friction washer. Whenever the crankshaft pulley is removed, a friction washer (base part number 6378) must be installed.

       If equipped, remove and discard the friction washer.

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55. Remove Special Service Tool: 303-1611-01 Adapter for 303-1611.

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56. Remove Special Service Tool: 303-1611-02 Adapter for 303-1611, Torque Multiplier.

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57. 1. Install Special Service Tool: 303-1602 Locking Tool, Crankshaft.
    2. Remove and discard the bolts.
    3. Remove flywheel or flexplate.
    4. Remove Special Service Tool: 303-1602 Locking Tool, Crankshaft.

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58. 1. Remove the bolts and the thermostat.
    2. Remove and discard the O-ring seals.

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59. 1. Install the original crankshaft pulley bolt.
    2. Remove and discard the crankshaft front seal. Use Special Service Tool: 303-409 (T92C-6700-CH) Remover, Crankshaft Seal.
    3. Remove and discard the crankshaft pulley bolt.

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60. Remove the bolt and the CKP sensor.

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61. 1. Remove and discard the bolts.
    2. Remove the oil pan.

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62. 1. Remove and discard the bolts.
    2. Remove the engine front cover.

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63. Remove and discard the gasket.

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64. WARNING: The tensioner is under spring tension. Be careful when handling the tensioner. Failure to follow this instruction may result in personal injury.
    • Rotate the timing belt tensioner clockwise.
    • Install a suitable locking pin.
    • Remove timing belt.

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65. WARNING: The tensioner is under spring tension. Be careful when handling the tensioner. Failure to follow this instruction may result in personal injury.

    Remove the bolt and the tensioner.

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66. 1. NOTE: Note the position of the component before removal.

       Remove the bolt, remove and discard the oil supply filter.

    2. Remove the timing drive pulley.

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67. NOTE: Use an open-ended wrench to prevent the component from turning.

    Remove the bolts and the VCT units.

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68. NOTE: Note the position of the components before removal.
    NOTE: Use a heat gun to soften the flange sealant, this will aid in the removal of the rear camshaft caps. Failure to follow these directions may result in damage to the camshaft caps.
    NOTE: Inspect the camshaft bores for any scratches that can be felt by hand.

    Loosen the camshaft bearing caps bolts in sequence, 2 turns at a time until all tension is released from the camshaft bearing caps and remove the bolts, caps and the camshafts. Use the General Equipment: Hot Air Gun

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

    Remove the valve tappets.

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70. 1. Using a Polydrive #10 bit, remove and discard the cylinder head bolts. Use the General Equipment: Polydrive Bit Socket
    2. Remove the cylinder head.

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71. Remove and discard the cylinder head gasket.

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    Refer to About This Information

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72. Check the cylinder head distortion. Refer to: Cylinder Head Distortion .
73. Check the cylinder block distortion. Refer to: Cylinder Block Distortion .
74. 1. Before removing the pistons, inspect the top of the cylinder bores.
    2. NOTE: Do not scratch the cylinder wall, remove all debris from the cylinder.

       If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad.

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75. • Remove the bolts and the crankshaft rear seal.
    • Discard the crankshaft rear seal.

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76. NOTE: Take extra care when handling the component.

    Remove the oil pump cover.

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77. Install a 4 mm drill bit into the balance shaft gear. Use the General Equipment: 4 mm Drill Bit

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78. Remove and discard the bolts.
    • Remove the oil pump and balance shaft gears.

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79. Remove the balance shaft weight.

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80. 1. Using a suitable tool, rotate the oil pump belt tensioner.
    2. Remove the oil pump belt.
    3. NOTE: Note the position of the component before removal.

       Remove the oil pump drive pulley.

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81. Remove the bolts and the oil pump belt tensioner.

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82. NOTE: Discard the bolts.

    Remove the bolts and the oil pump.

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83. Remove the alignment dowels.

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

    Remove the bolts and the connecting rod caps.

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85. NOTE: Note the position of the components before removal.
    NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

    Remove the pistons.

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

    Remove the connecting rod bearings.

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87. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.
    1. Remove the bolts and the main bearing caps.
    2. Remove the crankshaft.

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

    Remove the crankshaft main bearings.

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

    Remove the crankshaft main bearings.

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90. Remove the bolts and the engine piston oil cooler valves.

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