Section 1720 (Engine - 2.3L): Disassembly: Engine

WARNING: This page is about a different car, the 2006 Mercury Milan and 2006 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

SPECIAL TOOL DESCRIPTION

Courtesy of FORD MOTOR CO.	Engine Stand 014-00232 or equivalent
Courtesy of FORD MOTOR CO.	Alignment Plate, Camshaft 303-465 (T94P-6256-CH)
Courtesy of FORD MOTOR CO.	Timing Peg, Crankshaft 303-507
Courtesy of FORD MOTOR CO.	Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A)
Courtesy of FORD MOTOR CO.	Adapter for 205-126 (205-072-02)
Courtesy of FORD MOTOR CO.	Remover, Oil Seal 303-409 (T92C-6700-CH)

CAUTION: 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 you loosen the pulley bolt. 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.

CAUTION: 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.

CAUTION: Due to the precision fit and timing of the balancer shaft assembly, it cannot be removed from the engine block.

NOTE: For additional information, refer to the exploded views under Engine ASSEMBLY .

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 these instructions may result in personal injury.

CAUTION: 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 starter motor isolator.

Fig 2: Locating Starter Motor Isolator
Courtesy of FORD MOTOR CO.
Remove the 6 bolts and the flywheel.

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

Vehicles with automatic transaxle

Remove the 6 bolts and the flexplate.

Fig 4: Locating Flexplate Bolts
Courtesy of FORD MOTOR CO.

All vehicles

Mount the engine on a suitable stand.
Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt from the coolant pump pulley.
1. On early build engines, use the pulley bolt to rotate the tensioner.
2. On late build engines, use the hex feature to rotate the tensioner.
  
  Fig 5: Using Pulley Bolt To Rotate Tensioner And Using Hex Feature To Rotate Tensioner
  Courtesy of FORD MOTOR CO.
Remove the accessory drive belt from the engine.
On early build engines, remove the pin-type retainer, 2 bolts, shield and tensioner.

Fig 6: Locating Pin-Type Retainer, Bolts, Shield And Tensioner
Courtesy of FORD MOTOR CO.
On late build engines, remove the 2 bolts and the tensioner.

Fig 7: Locating Tensioner And Bolts
Courtesy of FORD MOTOR CO.
Disconnect the power steering pressure (PSP) switch electrical connector.

Fig 8: Locating Power Steering Pressure (PSP) Switch Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the 2 upper power steering pump bolts.

Fig 9: Locating Upper Power Steering Pump Bolts
Courtesy of FORD MOTOR CO.
Remove the lower bolt and the power steering pump.

Fig 10: Locating Power Steering Pump Lower And Bolt
Courtesy of FORD MOTOR CO.
Disconnect the knock sensor (KS) electrical connector and the 2 harness pin-type retainers.

Fig 11: Locating Knock Sensor (KS) Electrical Connector And Harness Pin-Type Retainers
Courtesy of FORD MOTOR CO.
Disconnect the lower radiator and heater hoses from the thermostat housing.
- Detach the radiator hose retainer clip from the intake manifold.
  
  Fig 12: Locating Lower Radiator And Heater Hoses From Thermostat Housing
  Courtesy of FORD MOTOR CO.
Disconnect the coolant hose from the throttle body and remove the hose from the engine.

Fig 13: Locating Coolant Hose
Courtesy of FORD MOTOR CO.
Disconnect the A/C compressor electrical connector.

Fig 14: Locating A/C Compressor Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the bolt and the A/C manifold.

Fig 15: Locating A/C Manifold And Bolt
Courtesy of FORD MOTOR CO.
Remove the 3 bolts and the A/C compressor.

Fig 16: Locating A/C Compressor And Bolts
Courtesy of FORD MOTOR CO.
Remove the 3 bolts and the coolant pump pulley.

Fig 17: 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 18: Locating Coolant Pump Bolts
  Courtesy of FORD MOTOR CO.
Remove the bolt and the accessory drive belt idler pulley.

Fig 19: Locating Accessory Drive Belt Idler Pulley Bolt
Courtesy of FORD MOTOR CO.
Disconnect the crankshaft position (CKP) sensor electrical connector and harness pin-type retainer.

Fig 20: Locating Crankshaft Position (CKP) Sensor Electrical Connector And Harness Pin-Type Retainer
Courtesy of FORD MOTOR CO.

NOTE: Whenever the CKP sensor is removed, a new one must be installed, using the alignment tool supplied with the new part.

Remove the 2 bolts and the CKP sensor.
- Discard the CKP sensor.
  
  Fig 21: Locating CKP Sensor Bolts
  Courtesy of FORD MOTOR CO.
Remove the 2 nuts and the generator splash shield.

Fig 22: Locating Generator Splash Shield And Nuts
Courtesy of FORD MOTOR CO.
Pull back the rubber boot and remove the nut.
- Disconnect the generator electrical connections and pin-type retainer.
  
  Fig 23: Locating Pin-Type Retainer And Generator Electrical Connections
  Courtesy of FORD MOTOR CO.
Remove the bolt, 2 stud bolts and the generator.

Fig 24: Locating Bolt, Stud Bolts And Generator
Courtesy of FORD MOTOR CO.

Vehicles with secondary air injection (AIR)

Disconnect the secondary air injection (AIR) hose from the catalytic converter.

Fig 25: Locating Secondary AIR Injection (AIR) Hose
Courtesy of FORD MOTOR CO.
Disconnect the AIR valve vacuum supply tube from the intake manifold.

Fig 26: Locating AIR Valve Vacuum Supply Tube
Courtesy of FORD MOTOR CO.
Disconnect the AIR valve electrical connector.

Fig 27: Locating AIR Valve Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the 2 bolts and the AIR valve, hoses and pump assembly from the engine.

Fig 28: Locating AIR Valve Bolts
Courtesy of FORD MOTOR CO.

All vehicles

NOTE: Vehicles equipped with AIR have 2 catalyst monitor sensors (CMS).

Fig 29: Locating CMS Electrical Connector

Courtesy of FORD MOTOR CO.

Disconnect the CMS electrical connector(s).
Disconnect the heated oxygen sensor (HO2S) electrical connector.

Fig 30: Locating Heated Oxygen Sensor (HO2S) Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the wiring harness bracket from the valve cover stud.

Fig 31: Locating Wiring Harness Bracket
Courtesy of FORD MOTOR CO.
Detach the wiring harness retainer from the valve cover stud.

Fig 32: Locating Wiring Harness Retainer
Courtesy of FORD MOTOR CO.

NOTE: Vehicles equipped with AIR do not require removal of the heat shield.

Fig 33: Locating Heat Shield And Screws

Courtesy of FORD MOTOR CO.

Remove the 6 screws and the heat shield.
Remove the 2 catalytic converter bracket bolts.

Fig 34: Locating Catalytic Converter Bracket Bolts
Courtesy of FORD MOTOR CO.
Remove 7 nuts, catalytic converter, gasket and the 7 studs.
- Discard the nuts, gasket and the studs.
  
  Fig 35: Locating Nuts, Catalytic Converter, Gasket And Studs
  Courtesy of FORD MOTOR CO.
If equipped, disconnect the block heater electrical connector.

Fig 36: Locating Block Heater Electrical Connector
Courtesy of FORD MOTOR CO.
If equipped, remove the block heater.

Fig 37: Locating Block Heater
Courtesy of FORD MOTOR CO.
Remove the 2 bolts and the catalytic converter bracket.

Fig 38: Locating Catalytic Converter Bracket And Bolts
Courtesy of FORD MOTOR CO.
Disconnect the coolant temperature sender electrical connector.

Fig 39: Locating Coolant Temperature Sender Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the exhaust gas recirculation (EGR) coolant hose and electrical connector.

Fig 40: Locating Exhaust Gas Recirculation (EGR) Coolant Hose And Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the oil pressure sender electrical connector.

Fig 41: Locating Oil Pressure Sender Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the manifold actual pressure (MAP) sensor electrical connector.

Fig 42: Locating Manifold Actual Pressure (MAP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the intake manifold runner control (IMRC) actuator electrical connector.

Fig 43: Locating Intake Manifold Runner Control (IMRC) Actuator Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the 2 swirl control valve electrical connectors.

Fig 44: Locating Swirl Control Valve Electrical Connectors
Courtesy of FORD MOTOR CO.
Detach the 2 wiring harness pin-type retainers from the intake manifold.

Fig 45: Locating Wiring Harness Pin-Type Retainers From Intake Manifold
Courtesy of FORD MOTOR CO.
Disconnect the electronic throttle body electrical connector.

Fig 46: Locating Electronic Throttle Body Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the 8 bolts and position the intake manifold aside to access the crankcase vent hose clamp and the EGR tube.
- Discard the gaskets.
  
  Fig 47: Locating Intake Manifold Bolts
  Courtesy of FORD MOTOR CO.
Disconnect the positive crankcase ventilation (PCV) hose and remove the intake manifold.

Fig 48: Locating Positive Crankcase Ventilation (PCV) Hose
Courtesy of FORD MOTOR CO.
Remove the EGR tube.

Fig 49: Locating EGR Tube
Courtesy of FORD MOTOR CO.
Remove the 3 bolts and the thermostat housing.

Fig 50: Locating Thermostat Housing Bolts
Courtesy of FORD MOTOR CO.
Disconnect the bypass hose from the cylinder block nipple.

Fig 51: Locating Bypass Hose From Cylinder Block Nipple
Courtesy of FORD MOTOR CO.
Disconnect the bypass hose from the coolant outlet and remove the bypass hose from the engine.

Fig 52: Locating Bypass Hose
Courtesy of FORD MOTOR CO.
Remove the bolt and the KS.

Fig 53: Locating KS And Bolt
Courtesy of FORD MOTOR CO.
Remove the 8 bolts and the crankcase vent oil separator.
- Discard the gasket.
  
  Fig 54: Locating Crankcase Vent Oil Separator And Bolts
  Courtesy of FORD MOTOR CO.
Remove and discard the engine oil filter.
Remove the 4 bolts and the oil filter adapter.
- Discard the gasket.
  
  Fig 55: Locating Oil Filter Adapter And Bolts
  Courtesy of FORD MOTOR CO.
Disconnect the camshaft position (CMP) sensor electrical connector.

Fig 56: Locating Camshaft Position (CMP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the variable camshaft timing (VCT) solenoid electrical connector.

Fig 57: Locating Variable Camshaft Timing (VCT) Solenoid Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the 4 coil-on-plug electrical connectors.

Fig 58: Locating Coil-On-Plug Electrical Connectors
Courtesy of FORD MOTOR CO.
Pull back the boot and disconnect the cylinder head temperature (CHT) sensor electrical connector.

Fig 59: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Detach the 2 pin-type harness retainers and remove the fuel supply rail insulator.

Fig 60: Locating Pin-Type Harness Retainers And Remove Fuel Supply Rail Insulator
Courtesy of FORD MOTOR CO.
Disconnect the 4 fuel injector electrical connectors.

Fig 61: Locating Fuel Injector Electrical Connectors
Courtesy of FORD MOTOR CO.

NOTE: Typical wiring harness retainers shown.

Fig 62: Locating Wiring Harness Retainers

Courtesy of FORD MOTOR CO.

Detach the remaining wiring harness retainers and remove the wiring harness from the engine.
Remove the 2 bolts and the fuel rail and injector assembly.

Fig 63: Locating Fuel Rail And Bolts
Courtesy of FORD MOTOR CO.
Remove the 4 bolts and the 4 coil-on-plug assemblies.

Fig 64: Locating Coil-On-Plug Assemblies And Bolts
Courtesy of FORD MOTOR CO.
Remove the oil level indicator.

Fig 65: Locating Oil Level Indicator
Courtesy of FORD MOTOR CO.
Loosen the 14 retainers and remove the valve cover.
- Discard the gaskets.
  
  Fig 66: Locating Valve Cover Retainers
  Courtesy of FORD MOTOR CO.

CAUTION: Failure to position the No. 1 piston 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 TDC.
- The hole in the crankshaft pulley should be in the 6 o'clock position.
  
  Fig 67: Using Crankshaft Pulley Bolt To Turn Crankshaft Clockwise
  Courtesy of FORD MOTOR CO.

CAUTION: The special tool 303-465 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 special tool cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.

Fig 68: Identifying Special Camshaft Tool (303-465)

Courtesy of FORD MOTOR CO.

Install the special tool in the slots on the rear of both camshafts.
Remove the engine plug bolt.

Fig 69: Locating Engine Plug Bolt
Courtesy of FORD MOTOR CO.

NOTE: The special tool 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 70: Identifying Special Tool (303-507)

Courtesy of FORD MOTOR CO.

Install the special tool.
Assemble the special tools using 4 hardened washers in the locations shown.

Fig 71: Locating Special Tools And Hardened Washers
Courtesy of FORD MOTOR CO.

CAUTION: 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 special tool and the bolt should be removed using an air impact wrench (1/2-in drive minimum).

CAUTION: If the crankshaft sprocket diamond washer comes off with the crankshaft pulley, it must be installed back onto the crankshaft.

Using the special tools and an air impact wrench, remove the crankshaft pulley.
- Remove and discard the crankshaft pulley bolt and washer.
- Remove the crankshaft pulley.
  
  Fig 72: Locating Crankshaft Pulley Bolt And Special Tools
  Courtesy of FORD MOTOR CO.

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

Fig 73: Locating Special Tool And Crankshaft Front Oil Seal

Courtesy of FORD MOTOR CO.

Using the special tool, remove the crankshaft front oil seal.
Remove the 22 bolts and the engine front cover.

Fig 74: Locating Engine Front Cover Bolts
Courtesy of FORD MOTOR CO.
Remove the timing chain tensioner.
1. Compress the timing chain tensioner and insert a paper clip into the hole to retain the tensioner.
2. Remove the 2 bolts and timing chain tensioner.
  
  Fig 75: Locating Timing Chain Tensioner Bolts And Paper Clip
  Courtesy of FORD MOTOR CO.
Remove the RH timing chain guide.

Fig 76: Locating RH Timing Chain Guide
Courtesy of FORD MOTOR CO.
Remove the timing chain.

Fig 77: Locating Timing Chain
Courtesy of FORD MOTOR CO.
Remove the 2 bolts and the LH timing chain guide.

Fig 78: Identifying Bolts And LH Timing Chain Guide
Courtesy of FORD MOTOR CO.

CAUTION: The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

Fig 79: Locating 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.

CAUTION: The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

Fig 80: Locating Intake Camshaft Phaser And Sprocket Bolt

Courtesy of FORD MOTOR CO.

Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the intake camshaft phaser and sprocket.
Remove the oil pump chain tensioner and guide.
1. Release the tension on the tensioner spring.
2. Remove the 2 shoulder bolts and the tensioner.
3. Remove the 2 shoulder bolts and the guide.
  
  Fig 81: Locating Tensioner Shoulder Bolts, Tensioner Spring And Guide
  Courtesy of FORD MOTOR CO.

NOTE: Remove the crankshaft sprocket diamond washers located in front of and 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 82: Locating Sprockets And Bolt
  Courtesy of FORD MOTOR CO.
Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.

Fig 83: Locating Camshaft Lobe
Courtesy of FORD MOTOR CO.
Remove the bolt and the VCT solenoid.

Fig 84: Locating VCT Solenoid And Bolt
Courtesy of FORD MOTOR CO.

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

Remove the camshafts from the engine.
- Loosen the camshaft bearing cap bolts, in the sequence shown, 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 85: Identifying Loosening Sequence Of Camshaft Bearing Caps Bolts
  Courtesy of FORD MOTOR CO.

CAUTION: 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 86: Locating Cylinder Head Bolts
  Courtesy of FORD MOTOR CO.
Remove the 2 cylinder head alignment dowels.

Fig 87: Identifying Cylinder Head Alignment Dowels
Courtesy of FORD MOTOR CO.
Remove the 13 bolts and the oil pan.

Fig 88: Locating Oil Pan Bolts
Courtesy of FORD MOTOR CO.
Remove the 6 bolts and the rear crankshaft seal.

Fig 89: Locating Rear Crankshaft Seal Bolts
Courtesy of FORD MOTOR CO.
Remove the 2 bolts, oil pump pickup tube and gasket.

Fig 90: Locating Oil Pump Pickup Tube Bolts
Courtesy of FORD MOTOR CO.
Remove the 4 bolts and the oil pump.

Fig 91: Locating Oil Pump 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 92: Installing Crankshaft TDC Timing Peg
Mark the balancer unit and shafts on the top for reference that the balancer unit is at TDC .

Fig 93: Locating Balancer Unit And Shafts Reference Mark
NOTE: Due to the precision interior construction of the balancer unit, it should not be disassembled.

Remove the 4 bolts and the balancer unit.

Fig 94: Locating Balancer Unit Bolts
Remove the Crankshaft TDC Timing Peg.

Fig 95: Installing Crankshaft TDC Timing Peg
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.

Remove the connecting rod cap bolts and cap.

Fig 96: Locating Connecting Rod Cap Bolts
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 97: Identifying Connecting Rod Installer
Remove the bolts in the sequence shown.
- Remove the main bearing beam.
- Discard the bolts.
Fig 98: Identifying Crankshaft Cap Bolts Removing Sequence
Remove the crankshaft from the engine block.

Fig 99: Locating Crankshaft
NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.

Remove the main bearings from the main bearing beam.

Fig 100: Locating Main Bearings
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 main bearings from the cylinder block.

Fig 101: Locating Main Bearings
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 4 oil squirters.

Fig 102: Locating Oil Squirters
Inspect the cylinder block, main bearing beam, pistons and connecting rods. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .