Engine - 2.3L: Disassembly: Engine

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

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.
1. Remove the 6 bolts, clutch pressure plate and clutch disc.
Fig 1: Locating Clutch Pressure Plate Bolts
Courtesy of FORD MOTOR CO.
2. Remove the starter motor isolator.
Fig 2: Locating Starter Motor Isolator
Courtesy of FORD MOTOR CO.
3. Remove the 6 bolts and the flywheel.
Fig 3: Locating Flywheel Bolts
Courtesy of FORD MOTOR CO.

Vehicles with automatic transaxle 

4. Remove the 6 bolts and the flexplate.
Fig 4: Locating Flexplate Bolts
Courtesy of FORD MOTOR CO.

All vehicles 

5. Mount the engine on a suitable stand.
6. Using the hex feature, rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt from the coolant pump pulley.
Fig 5: Rotating Accessory Drive Belt Tensioner Clockwise
Courtesy of FORD MOTOR CO.
7. Remove the accessory drive belt from the engine.
8. Remove the 2 bolts and the tensioner.
Fig 6: Locating Accessory Drive Belt Tensioner Bolts
Courtesy of FORD MOTOR CO.
9. Disconnect the power steering pressure (PSP) switch electrical connector.
Fig 7: Locating Power Steering Pressure (PSP) Switch Electrical Connector
Courtesy of FORD MOTOR CO.
10. Remove the 2 upper power steering pump bolts.
Fig 8: Locating Upper Power Steering Pump Bolts
Courtesy of FORD MOTOR CO.
11. Remove the lower bolt and the power steering pump.
Fig 9: Locating Power Steering Pump And Lower Bolt
Courtesy of FORD MOTOR CO.
12. Disconnect the knock sensor (KS) electrical connector and the 2 harness pin-type retainers.
Fig 10: Locating Knock Sensor (KS) Electrical Connector And Harness Pin-Type Retainers
Courtesy of FORD MOTOR CO.
13. Disconnect the lower radiator and heater hoses from the thermostat housing.
    • Detach the radiator hose retainer clip from the intake manifold.
Fig 11: Locating Lower Radiator And Heater Hoses From Thermostat Housing
Courtesy of FORD MOTOR CO.
14. Disconnect the coolant hose from the throttle body and remove the hose from the engine.
Fig 12: Locating Coolant Hose
Courtesy of FORD MOTOR CO.
15. Disconnect the A/C compressor electrical connector.
Fig 13: Locating A/C Compressor Electrical Connector
Courtesy of FORD MOTOR CO.
16. Remove the bolt and the A/C manifold.
Fig 14: Locating A/C Manifold And Bolt
Courtesy of FORD MOTOR CO.
17. Remove the 3 bolts and the A/C compressor.
Fig 15: Locating A/C Compressor Bolts
Courtesy of FORD MOTOR CO.
18. Remove the 3 bolts and the coolant pump pulley.
Fig 16: Locating Coolant Pump Pulley Bolts
Courtesy of FORD MOTOR CO.
19. Remove the 3 bolts and the coolant pump.
    • Remove and discard the O-ring seal.
Fig 17: Locating Coolant Pump Bolts
Courtesy of FORD MOTOR CO.
20. Remove the bolt and the accessory drive belt idler pulley.
Fig 18: Locating Accessory Drive Belt Idler Pulley Bolt
Courtesy of FORD MOTOR CO.
21. Disconnect the crankshaft position (CKP) sensor electrical connector and harness pin-type retainer.
Fig 19: 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.
22. Remove the 2 bolts and the CKP sensor.
    • Discard the CKP sensor.
Fig 20: Locating CKP Sensor Bolts
Courtesy of FORD MOTOR CO.
23. Remove the 2 nuts and the generator splash shield.
Fig 21: Locating Generator Splash Shield And Nuts
Courtesy of FORD MOTOR CO.
24. Pull back the rubber boot and remove the nut.
    • Disconnect the generator electrical connections and pin-type retainer.
Fig 22: Locating Pin-Type Retainer And Generator Electrical Connections
Courtesy of FORD MOTOR CO.
25. Remove the bolt, 2 stud bolts and the generator.
Fig 23: Locating Generator Bolt And Stud Bolts
Courtesy of FORD MOTOR CO.

Vehicles with secondary air injection (AIR) 

26. Disconnect the secondary air injection (AIR) hose from the catalytic converter.
Fig 24: Locating Secondary AIR Injection (AIR) Hose
Courtesy of FORD MOTOR CO.
27. Disconnect the AIR valve vacuum supply tube from the intake manifold.
Fig 25: Locating AIR Valve Vacuum Supply Tube
Courtesy of FORD MOTOR CO.
28. Disconnect the AIR valve electrical connector.
Fig 26: Locating AIR Valve Electrical Connector
Courtesy of FORD MOTOR CO.
29. Remove the 2 bolts and the AIR valve, hoses and pump assembly from the engine.
Fig 27: Locating Pump Assembly Bolts
Courtesy of FORD MOTOR CO.

All vehicles 

NOTE: Vehicles equipped with AIR have 2 catalyst monitor sensors (CMS).
30. Disconnect the CMS electrical connector(s).
Fig 28: Locating CMS Electrical Connector
Courtesy of FORD MOTOR CO.
31. Disconnect the heated oxygen sensor (HO2S) electrical connector.
Fig 29: Locating Heated Oxygen Sensor (HO2S) Electrical Connector
Courtesy of FORD MOTOR CO.
32. Remove the wiring harness bracket from the valve cover stud.
Fig 30: Locating Wiring Harness Bracket
Courtesy of FORD MOTOR CO.
33. Detach the wiring harness retainer from the valve cover stud.
Fig 31: Locating Wiring Harness Retainer
Courtesy of FORD MOTOR CO.
NOTE: Vehicles equipped with AIR do not require removal of the heat shield.
34. Remove the 6 screws and the heat shield.
Fig 32: Locating Heat Shield Screws
Courtesy of FORD MOTOR CO.
35. Remove the 2 catalytic converter bracket bolts.
Fig 33: Locating Catalytic Converter Bracket Bolts
Courtesy of FORD MOTOR CO.
36. Remove the 7 nuts, catalytic converter, gasket and the 7 studs.
    • Discard the nuts, gasket and the studs.
Fig 34: Locating Nuts, Catalytic Converter, Gasket And Studs
Courtesy of FORD MOTOR CO.
37. If equipped, disconnect the block heater electrical connector.
Fig 35: Locating Block Heater Electrical Connector
Courtesy of FORD MOTOR CO.
38. If equipped, remove the block heater.
Fig 36: Locating Block Heater
Courtesy of FORD MOTOR CO.
39. Remove the 2 bolts and the catalytic converter bracket.
Fig 37: Locating Catalytic Converter Bracket Bolts
Courtesy of FORD MOTOR CO.
40. Disconnect the coolant temperature sender electrical connector.
Fig 38: Locating Coolant Temperature Sender Electrical Connector
Courtesy of FORD MOTOR CO.
41. Disconnect the exhaust gas recirculation (EGR) coolant hose and electrical connector.
Fig 39: Locating Exhaust Gas Recirculation (EGR) Coolant Hose And Electrical Connector
Courtesy of FORD MOTOR CO.
42. Disconnect the oil pressure sender electrical connector.
Fig 40: Locating Oil Pressure Sender Electrical Connector
Courtesy of FORD MOTOR CO.
43. Disconnect the manifold actual pressure (MAP) sensor electrical connector.
Fig 41: Locating Manifold Actual Pressure (MAP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
44. Disconnect the intake manifold runner control (IMRC) actuator electrical connector.
Fig 42: Locating Intake Manifold Runner Control (IMRC) Actuator Electrical Connector
Courtesy of FORD MOTOR CO.
45. Disconnect the 2 swirl control valve electrical connectors.
Fig 43: Locating Swirl Control Valve Electrical Connectors
Courtesy of FORD MOTOR CO.
46. Detach the 2 wiring harness pin-type retainers from the intake manifold.
Fig 44: Locating Wiring Harness Pin-Type Retainers From Intake Manifold
Courtesy of FORD MOTOR CO.
47. Disconnect the electronic throttle body electrical connector.
Fig 45: Locating Electronic Throttle Body Electrical Connector
Courtesy of FORD MOTOR CO.
48. 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 46: Locating Intake Manifold Bolts
Courtesy of FORD MOTOR CO.
49. Disconnect the positive crankcase ventilation (PCV) hose and remove the intake manifold.
Fig 47: Locating Positive Crankcase Ventilation (PCV) Hose
Courtesy of FORD MOTOR CO.
50. Remove the EGR tube.
Fig 48: Locating Exhaust Gas Recirculation (EGR) Tube
Courtesy of FORD MOTOR CO.
51. Remove the 3 bolts and the thermostat housing.
Fig 49: Locating Thermostat Housing Bolts
Courtesy of FORD MOTOR CO.
52. Disconnect the bypass hose from the cylinder block nipple.
Fig 50: Locating Bypass Hose From Cylinder Block Nipple
Courtesy of FORD MOTOR CO.
53. Disconnect the bypass hose from the coolant outlet and remove the bypass hose from the engine.
Fig 51: Locating Bypass Hose To Coolant Outlet
Courtesy of FORD MOTOR CO.
54. Remove the bolt and the KS.
Fig 52: Locating Knock Sensor Bolt
Courtesy of FORD MOTOR CO.
55. Remove the 8 bolts and the crankcase vent oil separator.
    • Discard the gasket.
Fig 53: Locating Crankcase Vent Oil Separator And Bolts
Courtesy of FORD MOTOR CO.
56. Remove and discard the engine oil filter.
57. Remove the 4 bolts and the oil filter adapter.
    • Discard the gasket.
Fig 54: Locating Oil Filter Adapter And Bolts
Courtesy of FORD MOTOR CO.
58. Disconnect the camshaft position (CMP) sensor electrical connector.
Fig 55: Locating Camshaft Position (CMP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
59. Disconnect the variable camshaft timing (VCT) solenoid electrical connector.
Fig 56: Locating Variable Camshaft Timing (VCT) Solenoid Electrical Connector
Courtesy of FORD MOTOR CO.
60. Disconnect the 4 coil-on-plug electrical connectors.
Fig 57: Locating Coil-On-Plug Electrical Connectors
Courtesy of FORD MOTOR CO.
61. Pull back the boot and disconnect the cylinder head temperature (CHT) sensor electrical connector.
Fig 58: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector And Boot
Courtesy of FORD MOTOR CO.
62. Detach the 2 pin-type harness retainers and remove the fuel supply rail insulator.
Fig 59: Locating Pin-Type Harness Retainers And Remove Fuel Supply Rail Insulator
Courtesy of FORD MOTOR CO.
63. Disconnect the 4 fuel injector electrical connectors.
Fig 60: Locating Fuel Injector Electrical Connectors
Courtesy of FORD MOTOR CO.
NOTE: Typical wiring harness retainers shown.
64. Detach the remaining wiring harness retainers and remove the wiring harness from the engine.
Fig 61: Locating Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
65. Remove the 2 bolts and the fuel rail and injector assembly.
Fig 62: Locating Fuel Rail And Injector Assembly Bolts
Courtesy of FORD MOTOR CO.
66. Remove the 4 bolts and the 4 coil-on-plug assemblies.
Fig 63: Locating Coil-On-Plug Assemblies And Bolts
Courtesy of FORD MOTOR CO.
67. Remove the oil level indicator.
Fig 64: Locating Oil Level Indicator
Courtesy of FORD MOTOR CO.
68. Loosen the 14 retainers and remove the valve cover.
    • Discard the gaskets.
Fig 65: Locating Valve Cover Retainers
Courtesy of FORD MOTOR CO.
CAUTION: 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.
69. 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 66: Locating Hole On Crankshaft Pulley And Turning Crankshaft Clockwise
Courtesy of FORD MOTOR CO.
CAUTION: The special tool 303-465 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 special tool cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.
70. Install the special tool in the slots on the rear of both camshafts.
Fig 67: Identifying Special Camshaft Tool (303-465)
Courtesy of FORD MOTOR CO.
71. Remove the engine plug bolt.
Fig 68: 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.
72. Install the special tool.
Fig 69: Identifying Special Tool (303-507)
Courtesy of FORD MOTOR CO.
73. Assemble the special tools using 4 hardened washers in the locations shown.
Fig 70: Assembling Special Tools (205-126 And 205-072-02)
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.
74. 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 71: Locating Crankshaft Pulley Bolt And Special Tools (205-126, 205-072-02)
Courtesy of FORD MOTOR CO.
CAUTION: Use care not to damage the engine front cover or the crankshaft when removing the seal.
75. Using the special tool, remove the crankshaft front oil seal.
Fig 72: Removing Crankshaft Front Oil Seal Using Special Tool (303-409)
Courtesy of FORD MOTOR CO.
76. Remove the 22 bolts and the engine front cover.
Fig 73: Locating Engine Front Cover Bolts
Courtesy of FORD MOTOR CO.
77. 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 74: Locating Timing Chain Tensioner Bolt
Courtesy of FORD MOTOR CO.
78. Remove the RH timing chain guide.
Fig 75: Locating RH Timing Chain Guide
Courtesy of FORD MOTOR CO.
79. Remove the timing chain.
Fig 76: Locating Timing Chain
Courtesy of FORD MOTOR CO.
80. Remove the 2 bolts and the LH timing chain guide.
Fig 77: 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.
81. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the exhaust camshaft sprocket.
Fig 78: Locating Bolt And Exhaust Camshaft Sprocket
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.
82. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the intake camshaft sprocket.
Fig 79: Locating Intake Camshaft Phaser And Sprocket Bolt
Courtesy of FORD MOTOR CO.

Early build vehicles 

83. Remove the oil pump drive 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 80: Locating Tensioner Shoulder Bolts, Tensioner Spring And Guide
Courtesy of FORD MOTOR CO.

Late build vehicles 

84. 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 81: Locating Shoulder Bolts & Tensioner
Courtesy of FORD MOTOR CO.

All vehicles 

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.
85. Remove the oil pump chain and sprockets.
    1. Remove the bolt.
    2. Remove the chain and sprockets.
Fig 82: Identifying Chain & Sprockets
Courtesy of FORD MOTOR CO.
86. 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.
87. Remove the bolt and the VCT solenoid.
Fig 84: Locating Variable Camshaft Timing (VCT) Solenoid And Bolt
Courtesy of FORD MOTOR CO.
CAUTION: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.
88. 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 Cap 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.
89. Remove and inspect the valve tappets. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
90. 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.
91. Remove the 2 cylinder head alignment dowels.
Fig 87: Identifying Cylinder Head Alignment Dowels
Courtesy of FORD MOTOR CO.
92. Remove the 13 bolts and the oil pan.
Fig 88: Locating Oil Pan Bolts
Courtesy of FORD MOTOR CO.
93. Remove the 6 bolts and the rear crankshaft seal.
Fig 89: Locating Rear Crankshaft Seal Bolts
Courtesy of FORD MOTOR CO.
94. Remove the 2 bolts, oil pump pickup tube and gasket.
Fig 90: Locating Oil Pump Pickup Tube Bolts
Courtesy of FORD MOTOR CO.
95. Remove the 4 bolts and the oil pump.
Fig 91: Locating Oil Pump Bolts
Courtesy of FORD MOTOR CO.
96. 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

    
97. 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

    
98. 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

    
99. Remove the Crankshaft TDC  Timing Peg.
    Fig 95: Installing Crankshaft TDC Timing Peg

    
100. 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.
101. 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

     
102. 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

     
103. Remove the bolts in the sequence shown.
     • Remove the main bearing beam.
     • Discard the bolts.
     Fig 98: Identifying Crankshaft Cap Bolts Removing Sequence

     
104. Remove the crankshaft from the engine block.
     Fig 99: Locating Crankshaft

     
105. 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

     
106. 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

     
107. 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

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