Engine Mechanical - 2.0L: Disassembly: Engine

SPECIAL TOOLS

	Alignment Plate, Camshaft 303-465 (T94P-6256-CH)
	Engine Stand 014-00232 or equivalent
	2, 200# Floor Crane, Fold Away 300-OTC1819E
	Holding Tool, Crankshaft Damper 303-1416
	Holding Tool, Flywheel 303-103 (T74P-6375-A)
	Installer, Connecting Rod 303-462 (T94P-6136-AH)
	Remover, Oil Seal 303-409 (T92C-6700-CH)
	Spreader Bar 303-D089 (D93P-6001-A3) or equivalent
	Timing Peg, Crankshaft TDC 303-507

MATERIAL SPECIFICATIONS

Item	Specification
Motorcraft® Metal Surface Prep ZC-31-A	-
Motorcraft® Silicone Gasket Remover ZC-30	-

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: 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 view under the ASSEMBLY  procedure .

1. Install the Flywheel Holding Tool and remove the flywheel or flexplate.
   Fig 1: Identifying Flywheel Holding Tool On Flywheel

   Courtesy of FORD MOTOR CO.
2. Mount the engine on a suitable engine stand.
3. Loosen the bolt and remove the accessory drivebelt idler pulley.
   Fig 2: Locating Accessory Drive Belt Idler Pulley And Bolt

   Courtesy of FORD MOTOR CO.
4. Remove the 3 bolts and the coolant pump pulley.
   Fig 3: Locating Coolant Pump Pulley Bolts

   Courtesy of FORD MOTOR CO.
5. Remove the 3 bolts and the coolant pump.
   Fig 4: Locating Coolant Pump And Bolts

   Courtesy of FORD MOTOR CO.
6. Disconnect the oil cooler hose and lower radiator hose from the thermostat housing.
   Fig 5: Locating Oil Cooler Hose And Lower Radiator Hose From Thermostat Housing

   Courtesy of FORD MOTOR CO.
7. Disconnect the EGR valve coolant hose.
   Fig 6: Locating Coolant Hose Of EGR Valve

   Courtesy of FORD MOTOR CO.
8. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
   Fig 7: Locating Engine Oil Pressure Sensor Electrical Connector

   Courtesy of FORD MOTOR CO.
9. Disconnect the oil cooler hoses.
   Fig 8: Locating Oil Cooler Hoses

   Courtesy of FORD MOTOR CO.
NOTE: A new oil cooler must be installed or severe damage to the engine can occur.
10. Remove the bolt and the oil cooler.
    • Discard the oil cooler.
      Fig 9: Locating Oil Cooler And Bolt

      Courtesy of FORD MOTOR CO.
11. Remove the oil filter, 4 bolts and the oil filter adapter.
    • Discard the oil filter and gasket.
      Fig 10: Locating Oil Filter And Bolts

      Courtesy of FORD MOTOR CO.
12. Disconnect the 4 coil-on-plug and Camshaft Position (CMP) sensor electrical connectors.
    Fig 11: Locating Coil-On-Plug And Camshaft Position Sensor Electrical Connectors

    Courtesy of FORD MOTOR CO.
13. Position the rubber boot aside and disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
    Fig 12: Locating Cylinder Head Temperature Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
14. Detach the generator wiring harness retainer from the valve cover stud.
    Fig 13: Locating Generator Wiring Harness Retainer From Valve Cover Stud

    Courtesy of FORD MOTOR CO.
15. Disconnect the 4 fuel injector electrical connectors and detach the 5 wiring harness retainers from valve cover stud bolts and intake manifold.
    Fig 14: Locating Fuel Injector Electrical Connectors

    Courtesy of FORD MOTOR CO.
16. Remove the 2 bolts and the fuel rail with the fuel injectors.
    Fig 15: Locating Fuel Rail Bolts

    Courtesy of FORD MOTOR CO.
17. Disconnect the Knock Sensor (KS) electrical connector and pin-type retainer.
    Fig 16: Locating Knock Sensor Electrical Connector And Pin-Type Retainer

    Courtesy of FORD MOTOR CO.
18. Disconnect the throttle control electrical connector.
    Fig 17: Locating Throttle Control Electrical Connector

    Courtesy of FORD MOTOR CO.
19. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector.
    • Detach the 3 wiring harness retainers from the intake manifold.
      Fig 18: Locating Wiring Harness Retainers From Intake Manifold

      Courtesy of FORD MOTOR CO.
20. Disconnect the EGR valve electrical connector.
    Fig 19: Locating EGR Valve Electrical Connector

    Courtesy of FORD MOTOR CO.
21. Remove the lower intake manifold bolt.
    Fig 20: Identifying Lower Intake Manifold Bolt

    Courtesy of FORD MOTOR CO.
22. Remove the bolt and the oil level indicator tube.
    • Discard the O-ring seal.
      Fig 21: Locating Oil Level Indicator Tube Bolt

      Courtesy of FORD MOTOR CO.
NOTE: The 2 intake manifold bolts differ in length from rest of the bolts and also retain a crash bracket to the intake manifold. The 2 bolts are equipped with an attachment feature that allows them to be loosened but remain attached to the intake manifold. Do not attempt to remove the 2 bolts or the crash bracket from the intake manifold.
Fig 22: Locating Intake Manifold Bolts
Courtesy of FORD MOTOR CO.
23. Loosen the 2 intake manifold bolts.
24. Remove the 5 intake manifold bolts.
    Fig 23: 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.
25. Squeeze the 2 PCV hose connector tabs and disconnect the PCV hose from the intake manifold.
    • Remove the intake manifold.
      Fig 24: Locating PCV Hose Connector

      Courtesy of FORD MOTOR CO.
26. Remove the EGR tube.
    Fig 25: Identifying Exhaust Gas Recirculation Tube

    Courtesy of FORD MOTOR CO.
27. Remove the radio interference capacitor bracket bolt and position the bracket aside.
    Fig 26: Locating Radio Interference Capacitor Bracket With Bolt

    Courtesy of FORD MOTOR CO.
28. Disconnect the coolant bypass hose.
    Fig 27: Locating Coolant Bypass Hose

    Courtesy of FORD MOTOR CO.
29. Remove the 4 bolts and the coolant outlet.
    Fig 28: Locating Coolant Outlet Bolts

    Courtesy of FORD MOTOR CO.
30. Disconnect the coolant bypass hose.
    Fig 29: Locating Coolant Bypass Hose

    Courtesy of FORD MOTOR CO.
31. Remove the 3 bolts, thermostat housing and thermostat.
    Fig 30: Locating Thermostat Housing And Bolts

    Courtesy of FORD MOTOR CO.
32. Remove the 2 bolts, stud bolt and the A/C compressor.
    Fig 31: Locating A/C Compressor, Stud Bolts And Bolts

    Courtesy of FORD MOTOR CO.
33. Remove the bolt and the KS.
    Fig 32: Locating Bolt And Knock Sensor

    Courtesy of FORD MOTOR CO.
34. Remove the 8 bolts and the crankcase vent oil separator.
    Fig 33: Locating Crankcase Vent Oil Separator Mounting Bolts

    Courtesy of FORD MOTOR CO.
35. Remove the 3 bolts and the intermediate shaft bracket.
    Fig 34: Locating Intermediate Shaft Bracket And Bolts

    Courtesy of FORD MOTOR CO.
36. Remove the 4 bolts and the ignition coil-on-plugs.
    Fig 35: Locating Ignition Coil-On-Plug Bolts

    Courtesy of FORD MOTOR CO.
NOTE: Only use hand tools when removing or installing the spark plugs, damage can occur to the cylinder head or spark plug.
Fig 36: Locating Cylinder Head Temperature Sensor And Spark Plug
Courtesy of FORD MOTOR CO.
37. Remove the spark plugs and the CHT sensor.
38. Remove the bolts and the valve cover.
    Fig 37: Locating Valve Cover Bolts

    Courtesy of FORD MOTOR CO.
NOTE: 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.
39. 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 38: Turning Crankshaft Clockwise To Position No. 1 Piston At Top Dead Center

      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.
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 39: Checking Position Of Camshafts Using Camshaft Alignment Plate
Courtesy of FORD MOTOR CO.
40. Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
41. Remove the engine plug bolt.
    Fig 40: 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 41: Identifying Crankshaft TDC Timing Peg
Courtesy of FORD MOTOR CO.
42. 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.
43. 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 42: Locating Crankshaft Pulley Bolt And Washer

      Courtesy of FORD MOTOR CO.
NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal.
Fig 43: Removing Crankshaft Front Oil Seal Using Oil Seal Remover
Courtesy of FORD MOTOR CO.
44. Using the Oil Seal Remover, remove the crankshaft front seal.
45. Remove the 2 bolts and the CKP sensor.
    Fig 44: Locating CKP Sensor

    Courtesy of FORD MOTOR CO.
46. Remove the 22 bolts and the engine front cover.
    Fig 45: Locating Engine Front Cover Bolts

    Courtesy of FORD MOTOR CO.
47. 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 46: Compressing Timing Chain Tensioner Using Small Pick

       Courtesy of FORD MOTOR CO.
48. Remove the 2 bolts and the timing chain tensioner.
    Fig 47: Locating Timing Chain Tensioner Bolts

    Courtesy of FORD MOTOR CO.
49. Remove the RH timing chain guide.
    Fig 48: Locating RH Timing Chain Guide

    Courtesy of FORD MOTOR CO.
50. Remove the timing chain.
    Fig 49: Locating Timing Chain

    Courtesy of FORD MOTOR CO.
51. Remove the 2 bolts and the LH timing chain guide.
    Fig 50: Locating LH Timing Chain Guide Bolts

    Courtesy of FORD MOTOR CO.
NOTE: Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation. Damage to the tool or the camshaft can occur.
Fig 51: Locating Camshaft Drive Gear And Bolt
Courtesy of FORD MOTOR CO.
52. Using the flats on the camshaft to prevent camshaft rotation, remove the bolts and the camshaft sprockets.
53. 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 52: 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.
54. Remove the oil pump chain and sprockets.
    1. Remove the bolt.
    2. Remove the chain and sprockets.
       Fig 53: Identifying Oil Pump Chain And Sprockets

       Courtesy of FORD MOTOR CO.
55. Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.
    Fig 54: Locating Camshaft Lobe Position

    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.
56. Remove the camshafts from the engine.
    • Loosen the camshaft bearing bolts in the sequence shown in illustration, one turn at a time. Repeat until all the tension is released.
    • Remove the camshaft bearing caps.
    • Remove the camshafts.
      Fig 55: 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.
57. Remove the valve tappets.
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.
58. Inspect the valve tappets. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
59. Remove the cylinder head.
    • Remove and discard the 10 cylinder head bolts.
    • Remove the cylinder head.
    • Remove and discard the cylinder head gasket.
      Fig 56: Locating Cylinder Head Bolts

      Courtesy of FORD MOTOR CO.
60. Remove the cylinder head alignment dowels.
    Fig 57: Locating Cylinder Head Alignment Dowels

    Courtesy of FORD MOTOR CO.
NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
NOTE: Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.
NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.
61. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block in the following sequence.
    1. Remove any large deposits of silicone or gasket material with a plastic scraper.
    2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.
    3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
    4. Apply metal surface prep, following package directions, to remove any traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
62. 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 .
63. Remove the 13 bolts and the oil pan.
    Fig 58: Locating Oil Pan Bolt

    Courtesy of FORD MOTOR CO.
64. Remove the 6 bolts and the crankshaft rear seal with retainer plate.
    Fig 59: Locating Crankshaft Rear Seal Bolts

    Courtesy of FORD MOTOR CO.
65. Remove the 2 bolts, oil pump pickup tube and gasket.
    • Discard the gasket.
      Fig 60: Locating Bolts, Oil Pump Pickup Tube And Gasket

      Courtesy of FORD MOTOR CO.
66. Remove the 4 bolts and the oil pump.
    Fig 61: Locating Oil Pump Assembly Bolts

    Courtesy of FORD MOTOR CO.
67. Remove the Crankshaft TDC Timing Peg.
    Fig 62: Identifying Crankshaft TDC Timing Peg

    Courtesy of FORD MOTOR CO.
68. 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 63: Locating Connecting Rod Cap Bolts And Cap
Courtesy of FORD MOTOR CO.
69. Remove the connecting rod cap bolts and cap.
NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
70. 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 64: Removing Piston/Rod Assembly From Engine Block Using Connecting Rod Installer

      Courtesy of FORD MOTOR CO.
71. Remove the bolts in the sequence shown in illustration.
    • Remove the main bearing beam.
    • Discard the bolts.
      Fig 65: Identifying Crankshaft Cap Bolts Sequence

      Courtesy of FORD MOTOR CO.
72. Remove the crankshaft from the engine block.
    Fig 66: Locating Crankshaft Of Engine Block

    Courtesy of FORD MOTOR CO.
NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.
Fig 67: Locating Crankshaft Main Bearings
Courtesy of FORD MOTOR CO.
73. 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 68: Locating Crankshaft Main Bearings
Courtesy of FORD MOTOR CO.
74. 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 69: Locating Oil Squirters
Courtesy of FORD MOTOR CO.
75. Remove the 4 oil squirters.
76. Inspect the cylinder block, main bearing beam, pistons and connecting rods. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .