Section 16 (Engine - 2.5L DURATEC (125KW/170PS)): Disassembly: Engine
WARNING: This page is about a different variant/trim than selected.
For information on Ford Color Coded Illustrations refer to OEM Color Coding .
Special Tool(s) / General Equipment
| 205-153 (T80T-4000-W)Handle | |
|---|---|
| 300-OTC1819E2, 200# Floor Crane, Fold Away | |
| 303-103 (T74P-6375-A) Holding Tool, FlywheelT74P-77000-A | TKIT-2009TC-F | |
| 303-1247 VCT Spark Plug Tube Seal Remover and Installer | TKIT-2006UF-FLM | TKIT-2006UF-ROW | |
| 303-1416 Tool, Crank Damper Holding | TKIT-2008ET-FLM | |
| 303-409 (T92C-6700-CH)Remover, Crankshaft Seal | TKIT-1992-FH/FMH/FLMH | TKIT-1993-LMH/MH | |
| 303-465 Tool, Camshaft Align Timing | TKIT-1994-LMH/MH2 | TKIT-1994-FH/FMH/FLMH | |
| 303-507 Timing Peg, Crankshaft TDC | TKIT-2001N-FLM | TKIT-2001N-ROW | |
| Mounting Stand |
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. 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. All parts must be thoroughly cleaned and 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:
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:
Due to the precision construction of the balancer shaft assembly, it should not be disassembled.
NOTE:
For additional information, refer to the exploded views in DESCRIPTION AND OPERATION .
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- Install Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel.
- Remove the bolts and the flexplate.
- Discard the bolts.
- Mount the engine on a suitable stand. Use the General Equipment: Mounting Stand
- General Equipment: Spreader Bar Remove Special Service Tool: 300-OTC1819E 2, 200# Floor Crane, Fold Away.
- Remove the bolt, the stud bolt and the bracket.
- Remove the bolts and the accessory drive belt tensioner.
- Remove the bolt and the idler pulley.
- Remove the bolts and the coolant pump pulley.
- Remove the bolts and the coolant pump. Remove and discard the O-ring seal.
- Remove the bolts and the thermostat housing.
- Disconnect the EOP switch electrical connector.
- Remove the bolts and the oil filter adapter.
- Remove and discard the gasket.
- Remove the crankcase vent tube. Refer to: Quick Release Coupling
.
- Disconnect the CKP sensor electrical connector and detach the wire harness retainer.
- Detach the wire harness retainers.
- Disconnect the electrical connector and detach the wire harness retainers.
- Disconnect the VCT oil control solenoid electrical connector.
- Disconnect the ignition coil-on-plugs and CMP sensor electrical connectors.
- Position out the boot and disconnect the CHT sensor electrical connector.
- Disconnect the electrical connector and detach the wire harness retainer.
- Disconnect the fuel injector electrical connectors and detach the wire harness retainers.
- Detach the wire harness retainer.
- Disconnect the EVAP canister purge valve and TB (throttle body) electrical connectors.
- Disconnect the MAP sensor electrical connector and detach the wire harness retainers.
- Remove the nuts and position aside the bracket.
- Disconnect the EGR valve electrical connector.
- Detach the wire harness retainer and remove the engine wire harness.
- Remove the fuel rail insulator.
- Remove the nut and the radio capacitor.
- Remove the bolts and the fuel rail assembly.
- Remove the fuel injectors from the fuel rail.
- Remove and discard the fuel injector O-ring seals and the fuel injector clips.
- Remove the bolts and position out the intake manifold.
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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.
Squeeze the 2 crankcase vent oil separator tube tabs and disconnect the tube from the intake manifold.
- Remove the EGR tube.
- Release the clamps and remove the coolant by pass hose.
- Remove the bolt and the KS.
- Remove the bolts and the crankcase vent oil separator.
- If equipped.
- Remove the block heater.
- Remove the oil level indicator.
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NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.
Remove the bolts and the ignition coil-on-plugs.
- Loosen the fasteners and remove the valve cover.
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NOTE: The VCT solenoid seal should only be replaced if it is damaged.
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.
- Remove the bolts and the CKP sensor.
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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.
- Remove the engine plug bolt.
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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 disassembly.
- Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.
- Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at TDC.
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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 Special Service Tool: 303-465 Tool, Camshaft Align Timing.
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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: 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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NOTE: The crankshaft sprocket diamond washer may come off with the crankshaft pulley. The diamond washer should be cleaned and inspected for any damage. If damage is evident, replace the diamond washer. If no damage, the diamond washer is to be reused during installation. If the diamond washer is not installed, engine damage may occur.
If the diamond washer did not come off with the crankshaft pulley, remove the diamond washer.
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NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal.
Using the special tool, remove and discard the crankshaft front seal. Use Special Service Tool: 303-409 (T92C-6700-CH) Remover, Crankshaft Seal.
- Remove the bolts and the engine front cover.
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NOTE: If equipped with cast iron timing chain tensioner.
- Using a small pick, release and hold the ratchet mechanism.
- While holding the ratchet mechanism in the released position, compress the tensioner by pushing the timing chain arm toward the tensioner.
- Insert a holding pin into the hole to retain the tensioner.
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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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NOTE: If equipped with aluminum timing chain tensioner.
Remove the bolts and the timing chain tensioner.
- Remove the timing chain tensioner arm.
- Remove the timing chain.
- Remove the bolts and the timing chain guide.
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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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- Position out the spring.
- Remove the bolts and the oil pump chain tensioner.
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NOTE: The oil pump chain sprocket must be held in place.
- Remove the chain from the oil pump sprocket.
- Remove the bolt and the oil pump sprocket.
- Remove the crankshaft sprocket.
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NOTE: The diamond washer should be cleaned and inspected for any damage. If damage is evident, replace the diamond washer. If no damage, the diamond washer is to be reused during installation. If the diamond washer is not installed, engine damage may occur.
Remove the diamond washer.
- Remove the bolt and the VCT oil control solenoid.
- Remove Special Service Tool: 303-465 Tool, Camshaft Align Timing.
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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 cap bolts in sequence one turn at a time until all tension is released from the camshaft bearing caps. Remove the bolts, camshaft bearing caps and the camshafts.
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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.
- Inspect and install new parts, as necessary.
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- Remove the bolts and the cylinder head.
- Discard the bolts.
- Check the cylinder head distortion. Refer to: Cylinder Head Distortion .
- Remove and discard the cylinder head gasket.
- Remove the dowels.
- Check the cylinder block distortion. Refer to: Cylinder Block Distortion .
- Remove the bolts and the oil pan.
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- Remove the bolts and the crankshaft rear seal.
- Discard the crankshaft rear seal.
- Remove the bolts and the oil pump screen and oil pickup tube.
- Remove and discard the gasket.
- Remove the bolts and the oil pump.
- 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.
- Mark the balancer unit front shafts on the top for reference that the balancer unit is at TDC.
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NOTE: Due to the precision interior construction of the balancer unit, it should not be disassembled.
Remove the bolts and the balance shaft assembly.
- Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.
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- Visually inspect the top of the cylinder bores.
- Clean the specified component with the specified material.
- General Equipment: Abrasive pad
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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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NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
Remove the pistons.
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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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- Remove the bolts in sequence shown.
- Remove the main bearing beam.
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NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.
Remove the lower main bearing beam bearings.
- Remove the crankshaft.
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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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NOTE: If the oil squirters are being reused, mark them in order for correct location during reassembly.NOTE: The front bulkhead does not have an oil squirter.
Remove the oil squirters.
- Inspect the pistons. Refer to: Piston Inspection .
- Inspect the cylinder bore taper. Refer to: Cylinder Bore Taper .