Section 250 (Engine Mechanical - 2.0L DURATEC): Disassembly: Engine

WARNING: This page is about a different car, the 2014 Ford Focus. However, it is still accessible from the selected car via links, so may be relevant.

SPECIAL TOOL(S) DESCRIPTION

	205-153 (T80T-4000-W) Handle
	303-103 (T74P-6375-A) Holding Tool, Flywheel TKIT-2009TC-F T74P-77000-A
	303-1247/1
	303-1419 Remover, 3.5L/3.7L Stretchy Belt TKIT-2008SB-FLM
	303-1565 Alignment Tool, Camshaft TKIT-2010C-FLM TKIT-2010C-FLM
	303-409 (T92C-6700-CH) Remover, Crankshaft Seal TKIT-1992-FH/FMH/FLMH TKIT-1993-LMH/MH
	303-462 Installer, Connecting Rod
	303-507 Timing Peg, Crankshaft TDC TKIT-2001N-FLM TKIT-2001N-ROW
	303-D055 (D85L-6000-A) Strap Wrench
	307-005 (T59L-100-B) Slide Hammer
	310-205 Fuel Injector Brush
	310-206 Remover, Fuel Injector TKIT-2009A-FLM
Hose Clamp Remover/Installer

MATERIALS SPECIFICATION

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

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: 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: Place clean, lint-free shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.

NOTE: Early build engines have a 6-rib crankshaft pulley, late build engines have a 4-rib crankshaft pulley.

NOTE: Refer to EXPLODED VIEWS in Description and Operation.

WARNING: Do not breathe dust or use compressed air to blow dust from storage containers or friction components. Remove dust using government-approved techniques. Friction component dust may be a cancer and lung disease hazard. Exposure to potentially hazardous components may occur if dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or may lead to other chronic health effects. If irritation persists, seek medical attention or advice. Failure to follow these instructions may result in serious personal injury.

NOTE: Loosen the 6 clutch pressure plate-to-flywheel bolts evenly, by 2 turns at a time.

If equipped with a manual transmission.
If equipped with a manual transmission.
Use Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel .
If equipped with a automatic transmission.
Use Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel .
Mount the engine on a engine stand.
Refer to: QUICK RELEASE COUPLING .
Position the special tool between the crankshaft pulley and A/C compressor belt as shown in illustration below and rotate the crankshaft clockwise.
Use Special Service Tool: 303-1419 Remover, 3.5L/3.7L Stretchy Belt .
Rotate the crankshaft until the special tool is at approximately the 5 o'clock position as shown in illustration below.
Use Special Service Tool: 303-1419 Remover, 3.5L/3.7L Stretchy Belt .
Fold the special tool around the inside of the A/C compressor belt as shown in illustration below.
Use Special Service Tool: 303-1419 Remover, 3.5L/3.7L Stretchy Belt .
In one quick motion, firmly pull the special tool and remove the A/C compressor belt.
Use Special Service Tool: 303-1419 Remover, 3.5L/3.7L Stretchy Belt .
Loosen.
NOTE: Discard the O-ring seal.
Use the General Equipment: Hose Clamp Remover/Installer
NOTE: Remove the generator stud after generator is removed.
NOTE: Discard the thermostat housing gasket.
Refer to: QUICK RELEASE COUPLING .
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.
Use the General Equipment: Hose Clamp Remover/Installer
NOTE: Use care when removing the fuel injection pump noise insulator. Spreading the openings will aid in removing the fuel injection pump noise insulator and reduce the risk of damage.
NOTE: To release the fuel pressure in the high pressure fuel tube, wrap the fuel injection pump flare nut with a shop towel to absorb any residual fuel pressure during the loosening of fuel injection pump flare nut.
NOTE: Pull out the fuel rails in the direction of the fuel injector axis or damage may occur to the fuel injectors.

NOTE: Use compressed air and remove any dirt or foreign material from the cylinder head, block and general surrounding area of the fuel rail and injectors.

NOTE: When removing the fuel rails, the fuel injectors may remain in the fuel rails but normally remain in the cylinder heads and require the use of a Fuel Injector Remover tool to extract.
Remove any of the fuel injectors that remained in the head.
Use Special Service Tool: 307-005 (T59L-100-B) Slide Hammer ., 310-206 Remover, Fuel Injector .
Discard the specified component. Follow local disposal regulations.
NOTE: Make sure to thoroughly clean any residual fuel or foreign material from the cylinder head, block and the general surrounding area of the fuel rails and injectors.

NOTE: Do not use compressed air to clean the tip of the fuel injector.

NOTE: Do not use a brush to clean the tip of the fuel injector.

Clean the 4 fuel injector bores in the cylinder head.

Use Special Service Tool: 310-205 Fuel Injector Brush .
NOTE: Remove and discard the gasket.
NOTE: Remove and discard the gasket.
NOTE: The RH KS must be installed in the 6 o'clock position and the LH KS must be installed in the 4 o'clock position. Failure to follow these instructions may result in damage to the engine.

NOTE: Mark the location of the RH and LH KS .
NOTE: Alternately loosen the 2 fuel injection pump bolts one complete revolution at a time, remove the 2 bolts and fuel injection pump.
NOTE: Inspect and replace the gasket, if necessary.
NOTE: Inspect and replace the gasket, if necessary.
NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.
If equipped.
NOTE: Discard the valve cover gasket.
NOTE: The Variable Camshaft Timing (VCT) solenoid seals should only be replaced if they are damaged.

Use Special Service Tool: 205-153 (T80T-4000-W) Handle ., 303-1247/1.
Turn the crankshaft until piston no. 1 is 45 degrees before TDC by using the guide holes on the engine front cover and the crankshaft pulley.
NOTE: Failure to position the No. 1 piston at TDC can result in damage to the engine. Turn the engine in the normal direction of rotation only.

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 the crankshaft pulley removal and installation.

Install the special tool and using the crankshaft pulley bolt, turn the crankshaft clockwise slowly until contact is made with the special tool.

Use Special Service Tool: 303-507 Timing Peg, Crankshaft TDC ., 303-507 Timing Peg, Crankshaft TDC .
NOTE: The special tool is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

Install Special Service Tool: 303-1565 Alignment Tool, Camshaft .
NOTE: 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 crankshaft pulley 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.

Use Special Service Tool: 303-D055 (D85L-6000-A) Strap Wrench .
NOTE: The crankshaft sprocket diamond washer may come off with the crankshaft pulley. The diamond washer should be cleaned and inspected for any damage. If damage is evident, replace the diamond washer. If no damage, the diamond washer is to be reused during installation. If the diamond washer is not installed, engine damage may occur.

If the diamond washer did not come off with the crankshaft pulley, remove the diamond washer.
NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal.

Use Special Service Tool: 303-409 (T92C-6700-CH) Remover, Crankshaft Seal .
NOTE: Do not rely on the special tool to prevent camshaft rotation. Damage to the tool or the camshaft can occur.

Using a wrench on the flats of the exhaust camshaft to prevent camshaft rotation, loosen the exhaust camshaft phaser and sprocket bolt.
NOTE: The special tool is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

Using a wrench on the flats of the intake camshaft to prevent camshaft rotation, loosen the intake camshaft phaser and sprocket bolt.
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 holding pin into the hole to retain the tensioner.
NOTE: The phaser and sprocket bolts must be discarded and new installed.
NOTE: The special tool is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

Remove Special Service Tool: 303-1565 Alignment Tool, Camshaft .
NOTE: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.

NOTE: Note the position of the camshaft lobes on the No. 1 cylinder for installation reference.

NOTE: Mark the location and orientation of each camshaft bearing cap.
1. Loosen the camshaft bearing caps in sequence 2 turns at a time until all tension is released from the camshaft bearing caps.
2. Remove the camshaft bearing caps.
3. Remove the camshafts.
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.

Install new components as necessary.
NOTE: The cylinder head bolts must be discarded and new bolts must be installed. They are tighten-to-yield designed and cannot be reused.
NOTE: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.

NOTE: Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign material is removed.

NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.
1. Remove any large deposits of silicone or gasket material with a plastic scraper.
2. Apply Motorcraft Silicone Gasket Remover following package directions, and allow to set for several minutes.
  Material : Motorcraft® Silicone Gasket Remover/ZC-30-A
3. Remove the Motorcraft Silicone Gasket Remover with a plastic scraper. A second application of Motorcraft Silicone Gasket Remover may be required if residual traces of silicone or gasket material remain.
  Material : Motorcraft® Silicone Gasket Remover/ZC-30-A
4. Apply Motorcraft 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.
  Material : Motorcraft® Metal Surface Prep/ZC-31-A
NOTE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.

Support the cylinder head on a bench with the head gasket side up.

Refer to: CYLINDER HEAD DISTORTION .

Refer to: CYLINDER BLOCK DISTORTION .
NOTE: Discard the gasket.
1. Push the tensioner spring down and release the spring from under the shoulder bolt.
2. Remove the 2 shoulder bolts and the tensioner and chain.
NOTE: The diamond washer should be cleaned and inspected for any damage. If damage is evident, replace the diamond washer. If no damage, the diamond washer is to be reused during installation. If the diamond washer is not installed, engine damage may occur.

Remove the diamond washer.
Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC .
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.
NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

NOTE: Repeat until all the piston/rod assemblies are removed from the engine block.

Remove the piston/rod assembly from the engine block.

Use Special Service Tool: 303-462 Installer, Connecting Rod .
Refer to: PISTON INSPECTION .
NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.
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.
NOTE: If the engine piston oil coolers are being reused, mark them in order for correct location during reassembly.

NOTE: The front bulkhead does not have an engine piston oil cooler.