Ford Escape Quiz
Powertrain

Disassembly - Engine

In this manual: Powertrain
General Information — 26Chassis — 160Powertrain — 323Electrical — 356Body and Paint — 290
105steps
~660min
5/5difficulty
6special tools
Done 0 of 105

Special Service Tools / General Equipment

205-153 (T80T-4000-W)
Handle
303-1247
VCT Spark Plug Tube Seal Remover and Installer
TKIT-2006UF-FLM
TKIT-2006UF-ROW
303-1416
Tool, Crankshaft Damper Holder
TKIT-2008ET-FLM
303-409 (T92C-6700-CH)
Remover, Crankshaft Seal
TKIT-1992-FX/FMX/FLMX
TKIT-1993-LMX/MX
303-465
Camshaft Timing Tool
TKIT-1994-LMH/MH2
TKIT-1994-FX/FMX/FLMX
303-507
Timing Pin, Crankshaft TDC
TKIT-2001N-FLM
TKIT-2001N-RYAD
Floor crane
Mounting Stand
Plastic Scraper
Hose Clamp Removal/Installation Tool

Materials

Name Specification
Motorcraft® Silicone Gasket Remover
ZC-30-A, AZC-30-C		 -
Motorcraft® Metal Surface Preparation Wipes
ZC-31-B		 -
Motorcraft® Metal Brake Parts Cleaner
PM-4-A, PM-4-B, APM-4-C		 -

NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as specified in this procedure. The crankshaft pulley and crankshaft sprocket are not keyed to the crankshaft. The crankshaft, crankshaft sprocket and pulley are joined to each other by friction. For this reason, the crankshaft sprocket will also come loose 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 with special service tools, otherwise serious engine damage may occur.

NOTICE: 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 oil pan may cause engine failure.

  1. Remove the bolts and damper. Discard the bolts.
    • Remove the bolts and flywheel.
    • Discard the bolts.
  3. Install the engine on the mounting stand.
    Use common service equipment: mounting stand
  4. Remove the engine lifting equipment.
    Use common service equipment: floor crane
  5. Remove the coolant hoses.
    Use common service equipment: hose clamp removal/installation tool.
  6. Remove the brackets and the A/C compressor.
  7. Remove the bolts and the A/C bracket.
  8. Remove the brackets and the coolant pump.
  9. Remove the brackets and the coolant pump.
  10. Remove the coolant hose, the studs and the thermostat housing.
    Use the general equipment: hose clamp removal and installation tool.
  11. Disconnect the CKP electrical connector and remove the pin retainers.
  12. Disconnect the electrical connectors.
  13. Position the boot and disconnect the CHT sensor electrical connector.
  14. Disconnect the electrical connectors, remove the retainers and remove the wiring harness.
  15. Remove the pin-type retainer, the crankcase vent tube and the fuel feed line.
    Refer to: Quick Release Coupling (310-00G).
    Refer to: Spring Lock Couplings (310-00C Fuel System - General Information, General Procedures).
  16. Remove the bolts, the pin-type retainers and the fuel vapor tube.
    Refer to: Quick Release Coupling (310-00G).
  17. Remove the nut and the fuel line bracket.
  18. Disconnect the differential pressure sensor hoses.
  19. Remove the fasteners and remove the EGR differential pressure feedback sensor module.
    • Remove the EGR outlet tube brackets.
    • Remove the EGR attaching bolts.
  21. Remove and discard the EGR outlet tube gasket.
  22. Remove and discard the EGR cooler O-ring.
  23. Remove the EGR back pressure sensor.
    • Remove the EGR valve.
    • Remove and discard the gaskets.
  25. Remove the fasteners and the EGR outlet tube.
  26. Remove the exhaust gas recirculation cooler outlet temperature sensor.
  27. Remove the bolts, the water outlet adapter and the hoses.
  28. Disconnect the crankcase vent oil separator tube.
  29. Disconnect the wiring harness pin-type retainer, remove the bolts and the intake manifold.

    • Remove the bolts and the crankcase vent oil separator.
    • Remove the bolt and the KS.
    • Remove the bolts and the water inlet cover.
    • Remove the converter cover.
  31. If equipped.
    Remove the oil cooler.
  32. Remove the oil pressure sensor.
  33. Remove the bolts and the oil filter adapter.
  34. Remove and discard the gasket.
  35. Remove the bolts and the ignition coil-on-plug.
  36. Remove the nut and the radio capacitor.
  37. Remove the studs and the fuel rail assembly.
  38. Remove the fuel injectors from the fuel rail.
  39. Remove and discard the fuel injector O-rings and the fuel injector clips.
  40. Remove the oil level indicator.
  41. Remove the bolt and the camshaft phaser.
  42. Loosen the fasteners and remove the valve cover.
  43. Using the special tools, remove the VCT oil control solenoid valve seals.
    Use the special service tool: 303-1247 VCT Spark Plug Tube Seal Removal and Installation Tool, 205-153 (T80T-4000-W) Handle.
  44. Clean the valve cover gasket surfaces.
    Material: Motorcraft® metal surface preparation pads / ZC-31-B.
  45. Remove the bolts and the coolant outlet pipe.
  46. Remove the engine mount studs.
  47. Remove the bolts and the CKP sensor.
  48. Release the retainers and remove the crankshaft pulley cover.
  49. Using the crankshaft pulley bolt, rotate the crankshaft clockwise to position the No. 1 piston at TDC. The hole in the crankshaft pulley must be at the 6 o'clock position.
  50. Remove the engine plug bolt.
    • Install the special service tool: 303-507 Timing Pin, Crankshaft TDC.
    • Slowly rotate the crankshaft clockwise until the crankshaft balance weight contacts the crankshaft TDC timing pin. The engine is now at TDC.
  52. Install the Special Service Tool: 303-465 Camshaft Timing Tool.
  53. Install the recommended tool: 303-1416 Crankshaft Damper Holding Tool. The shown tool or a commercially available equivalent may be used.
    Use the special service tool: 303-507 Timing Pin, Crankshaft TDC.

  54. NOTICE: The crankshaft must remain at TDC during removal of the pulley bolt, or engine damage may occur. Therefore, the crankshaft pulley must be held in place with the Crankshaft Damper Holding Tool, and the bolt must be removed with an air impact wrench (minimum 1/2 inch).

    • Using the special tool, remove the crankshaft pulley bolt and pulley.
      Use the special service tool: 303-1416 Crankshaft Damper Holding Tool.
    • Discard the bolt and washer.
      Use the special service tool: 303-507 Crankshaft TDC Timing Pin.
  55. Using the special tool, remove and discard the front crankshaft seal.
    Use the Special Service Tools: 303-409 (T92C-6700-CH) Remover, Crankshaft Seal, 303-507 Timing Pin, Crankshaft TDC.
  56. Remove the bolts and the front engine cover.
  57. Make sure the mating surface is clean and free of foreign material.
    Refer to: RTV Sealing Surface Cleaning and Preparation (303-00 Engine System - General Information, General Procedures).
    Use the general equipment: plastic scraper.
    Material: Motorcraft® silicone gasket remover / ZC-30-A, AZC-30-C.
    Material: Motorcraft® metal brake parts cleaner / PM-4-A, PM-4-B, APM-4-C.
    Material: Motorcraft® metal surface preparation pads / ZC-31-B.
  58. Make sure the mating surface is clean and free of foreign material.
    Refer to: RTV Sealing Surface Cleaning and Preparation (303-00 Engine System - General Information, General Procedures).
    Use the general equipment: plastic scraper.
    Material: Motorcraft® silicone gasket remover / ZC-30-A, AZC-30-C.
    Material: Motorcraft® metal brake parts cleaner / PM-4-A, PM-4-B, APM-4-C.
    Material: Motorcraft® metal surface preparation pads / ZC-31-B.
  59. Remove the bolts and the timing chain tensioner.
  60. Remove the timing chain tensioner arm.
  61. Remove the timing chain.
  62. Remove the bolts and the timing chain guide.
  63. Remove the bolts and the camshaft sprockets.
    1. Position the spring.
    1. Remove the bolts and the oil pump chain tensioner.
    • Remove the chain from the oil pump drive sprocket.
    • Remove the bolt and the oil pump drive gear.
  66. Remove the crankshaft sprocket.
    Use the special service tool: 303-507 Crankshaft TDC Timing Pin.
  67. Remove the bolt and the VCT oil control solenoid.
  68. Remove the special service tool: 303-465 Camshaft Timing Tool.
  69. Loosen the camshaft bearing cap bolts one turn at a time, in sequence, until all tension is released from the camshaft bearing caps. Remove the bolts and the caps.
  70. Remove the camshafts.
  71. Remove the valve lifters.
  72. Inspect the valve lifters. If necessary, install new parts.
  73. Remove and discard the studs.
  74. If equipped.
    • Remove the heater core housing.
  75. Remove the bolts and the plug.
  76. Remove and discard the plug gasket.
    • Remove the bolts and the cylinder head.
    • Discard the bolts.
  78. Check the cylinder head for distortion.
    Refer to: Cylinder Head Distortion (303-00 Engine System - General Information, General Procedures).
  79. Clean the cylinder block sealing surfaces.
  80. Remove and discard the cylinder head gasket.
  81. Remove the locating pins.

  82. NOTICE: Do not use metal scrapers, wire brushes, discs or other abrasive materials to clean the sealing surfaces. These tools leave scratches and gouges that create leak paths. Use a plastic scraper to remove all traces of the cylinder head gasket.

    Clean the cylinder block sealing surfaces.
  83. Check the cylinder block for distortion.
    Refer to: Cylinder Block Distortion (303-00 Engine System - General Information, General Procedures).
  84. Remove the bolts and the oil pan.
  85. Make sure the mating surface is clean and free of foreign material.
    Refer to: RTV Sealing Surface Cleaning and Preparation (303-00 Engine System - General Information, General Procedures).
    Use the general equipment: plastic scraper.
    Material: Motorcraft® silicone gasket remover / ZC-30-A, AZC-30-C.
    Material: Motorcraft® metal brake parts cleaner / PM-4-A, PM-4-B, APM-4-C.
    Material: Motorcraft® metal surface preparation pads / ZC-31-B.
  86. Make sure the mating surface is clean and free of foreign material.
    Refer to: RTV Sealing Surface Cleaning and Preparation (303-00 Engine System - General Information, General Procedures).
    Use the general equipment: plastic scraper.
    Material: Motorcraft® silicone gasket remover / ZC-30-A, AZC-30-C.
    Material: Motorcraft® metal brake parts cleaner / PM-4-A, PM-4-B, APM-4-C.
    Material: Motorcraft® metal surface preparation pads / ZC-31-B.
    • Remove the bolts and the oil pickup tube.
    • Remove and discard the oil pickup tube gasket.
    • Remove the bolts and the rear crankshaft seal.
    • Discard the rear crankshaft seal.
  89. Remove the bolts and the oil pump.
  90. Remove and discard the oil pump gasket.
  91. Make sure the crankshaft TDC pin is still installed and the engine is still at TDC. Slowly rotate the crankshaft clockwise until the crankshaft counterweight is opposite the crankshaft TDC reference mark.
    Install the Special Service Tool: 303-507 Timing Pin, Crankshaft TDC.
  92. Mark the front balance shafts on top to make sure the balance shaft is at TDC.
  93. Remove the bolts and the balance shaft assembly.
  94. Remove the special service tool: 303-507 Camshaft/Crankshaft TDC Pin.
    1. Inspect the upper part of the cylinder bores.
    1. Clean the specified component with the specified material.
    • General equipment: Abrasive pad.
  96. Remove the bolts and the connecting rod caps.
  97. Remove the pistons.
  98. Remove the connecting rod bearings.
    • Remove the bolts in the specified sequence.
    • Remove the main bearing beam.
  100. Remove the lower main bearer bearings.
  101. Remove the crankshaft.
  102. Remove the upper crankshaft main bearings.
  103. Remove the oil spray nozzles.
  104. Inspect the pistons.
    Refer to: Piston Inspection (303-00 Engine System - General Information, General Procedures).
  105. Inspect the cylinder bore taper.
    Refer to: Cylinder Bore Taper (303-00 Engine System - General Information, General Procedures).

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