Section 1612 (Engine Mechanical - 2.5L (Except Hybrid)): Disassembly: Engine

WARNING: This page is about a different car, the 2012 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

SPECIAL TOOLS

	Alignment Plate, Camshaft 303-465 (T94P-6256-CH)
	Engine Stand 014-00232 or equivalent
	Holding Tool, Crankshaft Damper 303-1416
	Installer, Connecting Rod 303-462 (T94P-6136-AH)
	Remover, Oil Seal 303-409 (T92C-6700-CH)
	Timing Peg, Crankshaft TDC 303-507

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.

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 this instruction may result in serious personal injury.

NOTE: Loosen the 6 bolts evenly to prevent pressure plate damage.

Fig 1: Locating Clutch Pressure Plate Bolts

Courtesy of FORD MOTOR CO.

Remove the 6 bolts, clutch pressure plate and clutch disc.
Remove the 6 bolts and the flywheel.

Fig 2: Locating Flywheel Bolts
Courtesy of FORD MOTOR CO.

Vehicles with automatic transaxle
Remove the 6 bolts and the flexplate.

Fig 3: Locating Flexplate Bolts
Courtesy of FORD MOTOR CO.

All vehicles
Mount the engine on a suitable Engine Stand.
Using the hex feature, rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt from the engine.

Fig 4: Rotating Accessory Drive Belt Tensioner Clockwise And Removing Drive Belt From Engine
Courtesy of FORD MOTOR CO.
Remove the 2 bolts and the tensioner.

Fig 5: Locating Bolts And Tensioner
Courtesy of FORD MOTOR CO.
Remove the bolt and the accessory drive belt idler pulley.

Fig 6: Locating Accessory Drive Belt Idler Pulley Bolt
Courtesy of FORD MOTOR CO.
Remove the 3 bolts and the coolant pump pulley.

Fig 7: Locating Coolant Pump Pulley Bolts
Courtesy of FORD MOTOR CO.
Remove the 3 bolts and the coolant pump.
- Remove and discard the O-ring seal.
  
  Fig 8: Locating Coolant Pump And Bolts
  Courtesy of FORD MOTOR CO.
Disconnect the Knock Sensor (KS) electrical connector.

Fig 9: Locating Knock Sensor (KS) Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the 2 bolts and the accessory drive belt idler pulley and bracket.

Fig 10: Locating Bolts And Accessory Drive Belt Idler Pulley Bracket
Courtesy of FORD MOTOR CO.
Disconnect the coolant hose from the EGR valve.

Fig 11: Locating Coolant Hose Of EGR Valve
Courtesy of FORD MOTOR CO.
Remove the coolant tube retainer from the intake manifold.

Fig 12: Locating Coolant Tube Retainer
Courtesy of FORD MOTOR CO.
Remove the 3 bolts and the thermostat housing assembly.

Fig 13: Locating Thermostat Housing And Bolts
Courtesy of FORD MOTOR CO.
Disconnect the Crankshaft Position (CKP) sensor electrical connector and detach the wiring harness pin-type retainer.

Fig 14: Locating CKP Sensor Electrical Connector And Wiring Harness Pin-Type Retainer
Courtesy of FORD MOTOR CO.
Disconnect the Heated Oxygen Sensor (HO2S) electrical connector and detach the 2 wiring harness retainers from the generator stud bolts.

Fig 15: Locating Heated Oxygen Sensor (HO2S) Electrical Connector And Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
Disconnect the Variable Camshaft Timing (VCT) electrical connector and detach the wiring harness retainer from the valve cover stud bolt.

Fig 16: Locating Variable Camshaft Timing (VCT) Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the 2 nuts, 1 bolt and the generator.

Fig 17: Locating Generator With Nuts And Bolts
Courtesy of FORD MOTOR CO.
Remove the 2 generator studs.

Fig 18: Locating Generator Studs
Courtesy of FORD MOTOR CO.
Remove the 2 bolts and the exhaust flexible pipe bracket.

Fig 19: Locating Exhaust Flexible Pipe Bracket With Mounting Bolts
Courtesy of FORD MOTOR CO.
Remove the 4 exhaust manifold heat shield bolts and the heat shield.

Fig 20: Locating Exhaust Manifold Heat Shield Bolts And Heat Shield
Courtesy of FORD MOTOR CO.
Remove and discard the 7 exhaust manifold nuts.

Fig 21: Locating Exhaust Manifold Nuts
Courtesy of FORD MOTOR CO.
Remove the exhaust manifold and discard the exhaust manifold gasket.
Clean and inspect the exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
Remove and discard the 7 cylinder head studs.

Fig 22: Locating Cylinder Head Studs
Courtesy of FORD MOTOR CO.
Remove the bolt and the A/C manifold tube.
- Discard the 2 O-ring seals.
  
  Fig 23: Locating A/C Manifold Tube And Bolt
  Courtesy of FORD MOTOR CO.
Remove the 3 bolts and the A/C compressor.

Fig 24: Locating A/C Compressor Bolts
Courtesy of FORD MOTOR CO.
Disconnect the Engine Oil Pressure (EOP) switch electrical connector.

Fig 25: Locating Engine Oil Pressure Switch Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the 4 bolts and the oil filter adapter.
- Discard the gasket.
  
  Fig 26: Locating Bolts And Oil Filter Adapter
  Courtesy of FORD MOTOR CO.
Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector.

Fig 27: Locating Manifold Absolute Pressure Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the electronic throttle control and Evaporative Emission (EVAP) canister purge valve electrical connectors.

Fig 28: Locating Electronic Throttle Control And Evaporative Emission Canister Purge Valve Electrical Connectors
Courtesy of FORD MOTOR CO.
Detach the 2 wiring harness retainers from the intake manifold.

Fig 29: Locating Wiring Harness Retainers Of Intake Manifold
Courtesy of FORD MOTOR CO.
Disconnect the EGR valve electrical connector.

Fig 30: Locating EGR Valve Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the radio capacitor electrical connector.

Fig 31: Locating Radio Capacitor Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the 4 fuel injector electrical connectors.
- Detach the 2 wiring harness retainers and remove the wiring harness assembly.
  
  Fig 32: Locating Fuel Injector Electrical Connectors
  Courtesy of FORD MOTOR CO.
Disconnect the 4 ignition coil-on-plugs and Camshaft Position (CMP) sensor electrical connectors.

Fig 33: Locating Ignition Coil-On-Plugs And Camshaft Position Sensor Electrical Connectors
Courtesy of FORD MOTOR CO.
Position the rubber boot aside and disconnect the Cylinder Head Temperature (CHT) sensor electrical connector and remove the wiring harness.

Fig 34: Locating Rubber Boot And Cylinder Head Temperature Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the fuel rail insulator.

Fig 35: Locating Fuel Rail Insulator
Courtesy of FORD MOTOR CO.
Remove the nut and the radio capacitor.

Fig 36: Locating Nut And Radio Capacitor
Courtesy of FORD MOTOR CO.
Remove the 2 stud bolts, fuel rail and fuel injectors as an assembly.

Fig 37: Locating Stud Bolts, Fuel Rail And Fuel Injectors
Courtesy of FORD MOTOR CO.
Remove the 7 bolts (3 shown in illustration) and position the intake manifold aside.

Fig 38: Locating Intake Manifold Bolts
Courtesy of FORD MOTOR CO.

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.

Fig 39: Locating Crankcase Vent Oil Separator Tube Tab

Courtesy of FORD MOTOR CO.

Squeeze the 2 crankcase vent oil separator tube tabs and disconnect the tube from the intake manifold.
Remove the EGR tube.

Fig 40: Locating EGR Tube
Courtesy of FORD MOTOR CO.
Disconnect the bypass hose.

Fig 41: Locating Coolant Bypass Hose
Courtesy of FORD MOTOR CO.
Remove the bypass hose from the coolant outlet.

Fig 42: Locating Coolant Outlet Bypass Hose
Courtesy of FORD MOTOR CO.
Remove the bolt and the KS.

Fig 43: Locating Bolt And Knock Sensor
Courtesy of FORD MOTOR CO.
Remove the 8 bolts and the crankcase vent oil separator.

Fig 44: Locating Bolts And Crankcase Vent Oil Separator
Courtesy of FORD MOTOR CO.
If equipped, remove the block heater.

Fig 45: Locating Block Heater
Courtesy of FORD MOTOR CO.
Remove the oil level indicator.

Fig 46: Locating Oil Level Indicator
Courtesy of FORD MOTOR CO.

NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.

Fig 47: Locating Bolts And Coil-On-Plugs

Courtesy of FORD MOTOR CO.

Remove the 4 bolts and the 4 coil-on-plugs.
Remove the 14 retainers and the valve cover.

Fig 48: Locating Retainers And Valve Cover
Courtesy of FORD MOTOR CO.
Remove the 2 bolts and the CKP sensor.

Fig 49: Locating CKP Sensor And Bolts
Courtesy of FORD MOTOR CO.

NOTE: Failure to position the No. 1 position at Top Dead Center (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 Top Dead Center (TDC).
- The hole in the crankshaft pulley should be in the 6 o'clock position.
  
  Fig 50: Positioning Crankshaft Pulley Hole At 6 O'Clock Position
  Courtesy of FORD MOTOR CO.

NOTE: The Camshaft Alignment Plate is for camshaft alignment only. Using this 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.

Fig 51: Identifying Camshaft Alignment Plate (303-465)

Courtesy of FORD MOTOR CO.

Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
Remove the engine plug bolt.

Fig 52: Locating Engine Plug Bolt
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 disassembly.

Fig 53: Locating Crankshaft TDC Timing Peg

Courtesy of FORD MOTOR CO.

Install the Crankshaft TDC Timing Peg.

NOTE: The crankshaft must remain in the Top Dead Center (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. The diamond washer must be replaced, remove and discard the diamond washer. If the diamond washer is not installed, engine damage may occur.

Use the Crankshaft Damper Holding Tool and a suitable 1/2-in drive hand tool to hold the crankshaft pulley.
Use an air impact wrench to remove the crankshaft pulley bolt.
- Remove and discard the crankshaft pulley bolt and washer.
- Remove the crankshaft pulley.
- Remove the diamond washer and discard.
  
  Fig 54: Holding Crankshaft Pulley Bolt Using Crankshaft Damper Holding Tool
  Courtesy of FORD MOTOR CO.

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

Fig 55: Removing Crankshaft Front Oil Seal Using Oil Seal Remover (303-409)

Courtesy of FORD MOTOR CO.

Using the Oil Seal Remover, remove the crankshaft front oil seal.
Remove the 22 bolts and the engine front cover.

Fig 56: Locating Engine Front Cover Bolts
Courtesy of FORD MOTOR CO.
Compress the timing chain tensioner in the following sequence.
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 paper clip into the hole to retain the tensioner.
  
  Fig 57: Compressing Timing Chain Tensioner
  Courtesy of FORD MOTOR CO.
Remove the 2 bolts and timing chain tensioner.

Fig 58: Locating Timing Chain Tensioner Bolts
Courtesy of FORD MOTOR CO.
Remove the RH timing chain guide.

Fig 59: Locating RH Timing Chain Guide
Courtesy of FORD MOTOR CO.
Remove the timing chain.

Fig 60: Locating Timing Chain
Courtesy of FORD MOTOR CO.
Remove the 2 bolts and the LH timing chain guide.

Fig 61: Locating LH Timing Chain Guide Bolts
Courtesy of FORD MOTOR CO.

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

Fig 62: Locating Flats On Camshaft, Bolt And Exhaust Camshaft Sprocket

Courtesy of FORD MOTOR CO.

Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the exhaust camshaft sprocket.

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

Fig 63: Locating Flats On Camshaft, Bolt And Camshaft Phaser And Sprocket

Courtesy of FORD MOTOR CO.

Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the intake camshaft sprocket.
Remove the oil pump drive chain tensioner.
1. Release the tension on the tensioner spring.
2. Remove the tensioner and the 2 shoulder bolts.
  
  Fig 64: Identifying Oil Pump Chain Drive Tensioner And Shoulder Bolts
  Courtesy of FORD MOTOR CO.

NOTE: Remove and discard the crankshaft sprocket diamond washer located behind the crankshaft sprocket.

NOTE: The oil pump chain sprocket must be held in place.

Remove the oil pump chain and sprockets.
1. Remove the bolt.
2. Remove the chain and sprockets.
  
  Fig 65: Identifying Bolt And Oil Pump Chain Sprockets
  Courtesy of FORD MOTOR CO.
Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.

Fig 66: Locating Camshaft Lobe Position
Courtesy of FORD MOTOR CO.
Remove the bolt and the VCT solenoid.

Fig 67: Locating Variable Camshaft Timing Solenoid And Mounting Bolt
Courtesy of FORD MOTOR CO.
Remove the plug and the VCT system oil filter from the intake camshaft thrust cap.

Fig 68: Locating Plug And VCT System Oil Filter
Courtesy of FORD MOTOR CO.

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.

Remove the camshafts from the engine.
- Loosen the camshaft bearing cap bolts, in the sequence shown in illustration, one turn at a time until all tension is released from the camshaft bearing caps.
- Remove the bolts and the camshaft bearing caps.
- Remove the camshafts.
  
  Fig 69: Identifying Camshaft Bearing Cap Bolts Loosening Sequence
  Courtesy of FORD MOTOR CO.

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 and inspect the valve tappets. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
Remove the cylinder head.
- Remove and discard the 10 cylinder head bolts.
- Remove the cylinder head.
- Remove and discard the cylinder head gasket.
  
  Fig 70: Locating Cylinder Head Bolts
  Courtesy of FORD MOTOR CO.
Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
Remove the 2 cylinder head alignment dowels.

Fig 71: Locating Cylinder Head Alignment Dowels
Courtesy of FORD MOTOR CO.
Remove the 13 bolts and the oil pan.

Fig 72: Locating Oil Pan Bolts
Courtesy of FORD MOTOR CO.
Remove the 6 bolts and the rear crankshaft seal.

Fig 73: Locating Crankshaft Rear Seal Bolts
Courtesy of FORD MOTOR CO.
Remove the 2 bolts, oil pump pickup tube and gasket.

Fig 74: Locating Bolts, Oil Pump Pickup Tube And Gasket
Courtesy of FORD MOTOR CO.
Remove the 4 bolts and the oil pump.

Fig 75: Locating Oil Pump Assembly Bolts
Courtesy of FORD MOTOR CO.
Make sure the Crankshaft TDC Timing Peg is still installed and the engine is still at Top Dead Center (TDC).
- Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg.
  
  Fig 76: Installing Crankshaft TDC Timing Peg
  Courtesy of FORD MOTOR CO.
Mark the balancer unit and shafts on the top for reference that the balancer unit is at TDC.

Fig 77: Locating Balancer Unit And Shafts Reference Mark
Courtesy of FORD MOTOR CO.

NOTE: Due to the precision interior construction of the balancer unit, it should not be disassembled.

Fig 78: Locating Balancer Unit Bolts

Courtesy of FORD MOTOR CO.

Remove the 4 bolts and the balancer unit.
Remove the Crankshaft TDC Timing Peg.

Fig 79: Installing Crankshaft TDC Timing Peg
Courtesy of FORD MOTOR CO.
Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad or equivalent, following manufacturer's instructions.

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

Fig 80: Locating Connecting Rod Cap Bolts

Courtesy of FORD MOTOR CO.

Remove the connecting rod cap bolts and cap.

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

Using the Connecting Rod Installer, remove the piston/rod assembly from the engine block.
- Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine block.
  
  Fig 81: Removing Piston/Rod Assembly From Engine Block Using Connecting Rod Installer (303-462)
  Courtesy of FORD MOTOR CO.
Remove the bolts in the sequence shown in illustration.
- Remove the main bearing beam.
- Discard the bolts.
  
  Fig 82: Identifying Crankshaft Cap Bolts Removing Sequence
  Courtesy of FORD MOTOR CO.
Remove the crankshaft from the engine block.

Fig 83: Locating Crankshaft Gear
Courtesy of FORD MOTOR CO.

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

Fig 84: Locating Crankshaft Main Bearings

Courtesy of FORD MOTOR CO.

Remove the main bearings from the main bearing beam.

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 85: Locating Crankshaft Thrust Bearing

Courtesy of FORD MOTOR CO.

Remove the main bearings from the cylinder block.

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.

Fig 86: Locating Oil Squirters

Courtesy of FORD MOTOR CO.

Remove the 4 oil squirters.
Inspect the cylinder block, main bearing beam, pistons and connecting rods. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .