Engine - 2.0L Zetec: Overhaul Ford Escape I

Disassembly

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1. Using the special tool, lock the flywheel to the engine.
2. Remove the bolts, clutch pressure plate and clutch disc.
3. Remove the flywheel.
4. Remove the special tool.
5. Remove rear cover plates and dowels.
6. Using the special tool, remove the crankshaft rear seal.
7. Inspect the crankshaft rear oil seal area.
8. Use the special tool to remove the pilot bearing. Install the special tool. Remove the pilot bearing.
9. Mount the engine on a suitable engine stand.
10. Remove the bolt and the oil level indicator and tube.
11. Remove the six bolts and three nuts and remove the exhaust manifold. Discard the gasket.
12. Remove the power steering pump bracket.
13. Remove the A/C compressor bracket.
14. Remove the coolant tube. Remove the bolt and nut. Disconnect the hose.
15. Remove the crankshaft position (CKP) sensor.
16. Remove the crankcase vent oil separator. Disconnect the positive crankcase ventilation (PCV) valve. Remove the bolts and remove the separator. Discard the gasket.
17. Remove the coolant tube. Remove the bolt. Disconnect the hose.
18. Remove the bolt and remove the crankshaft pulley.
19. Remove the accessory drive belt idler pulley.
20. Remove the lower timing belt cover.
21. Remove the water pump pulley.
22. Remove the lower engine mount bracket.
23. Disconnect the wire harness.
24. Remove the upper timing belt cover.
25. Remove the timing belt tensioner and remove and discard the timing belt.
26. Remove the water pump adapter.
27. Remove the timing belt idler pulley.
28. Remove the ignition wires from the spark plugs.
29. Disconnect the wire harness and position aside.
30. Remove the valve cover. Remove the studbolts. Remove the bolts.
31. Remove the bolts and the camshaft timing sprockets.
32. Remove the camshafts. Loosen the camshaft journal cap bolts in several two-turn passes in the sequence shown. Remove the bolts. Remove the caps.
33. Remove the valve tappets from the cylinder head.
34. Remove the inner timing belt cover.
35. Remove the generator.
36. Remove the generator bracket.
37. Disconnect the following electrical connectors and remove the fuel charging wiring harness from the engine: cylinder temperature sensor Throttle position sensor Wiring harness to vehicle Idle air control valve Camshaft position sensor fuel injectors
38. Disconnect EGR tube fitting.
39. Remove the EGR tube.
40. Remove the coil and bracket assembly.
41. Remove the thermostat housing. Inspect and install a new O-ring seal if damaged.
42. Remove the PCV tube.
43. Remove the intake manifold. Remove the two nuts and five bolts in the sequence shown.
44. Remove the oil pressure sensor.
45. Remove the block heater if equipped.
46. Remove the knock sensor.
47. Remove the oil cooler.
48. Remove the crankshaft sprocket and timing belt guide.
49. Remove the cylinder head using the sequence shown. Discard the gasket. Discard the bolts.
50. Remove the 17 bolts and the oil pan.
51. Remove the bolts and the oil pump cover and screen. Carefully remove and discard the oil pump inlet tube gasket.
52. Remove the lower cylinder block and the gasket.
53. Remove the seven bolts and the oil pump. Remove the oil pump to cylinder block gasket.
54. Remove the rear main oil seal retainer assembly and discard the gasket.
55. Remove the four connecting rod caps.
56. If the connecting rod bearings are to be reused, each one must be identified so that it can be installed in its original location. Remove the four upper and four lower connecting rod bearings.
57. Use a suitable tool and remove the cylinder ridge.
58. Remove the four piston and connecting rod assemblies.
59. Remove the bolts and remove the crankshaft main bearing caps and bearings.
60. Remove the crankshaft.
61. Remove the upper crankshaft main bearings.
62. Remove the Woodruff key.

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1. Remove the camshaft sensor.
2. Remove the ignition coil bracket.
3. Remove the intake manifold.
4. Remove the exhaust manifold.
5. Remove the timing belt tensioner and pulley.
6. Remove the inner timing belt cover.
7. Remove the bracket.
8. Remove the rear lifting eye.
9. Remove the front lifting eye.
10. Remove the cylinder head temperature (CHT) sensor.
11. Using the special tools, compress the valve spring and remove the valve spring retainer keys, the valve spring retainers, and the valve springs. Remove the special tools.
12. Inspect the valve spring, valve spring retainer and valve spring retainer key. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-204610) . Install new parts as necessary.
13. Remove the valves.
14. Using the special tools, remove and discard the valve stem seals.
15. Inspect the valves. For additional information refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-204610) . Install new parts as necessary.

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1. Install the valves.
2. Lubricate valve and guides with Super Premium SAE 5W-20 Motor Oil or equivalent meeting Ford specification WSSM2C153- H and using the special tool install the valve stem seals onto the cylinder head valve guides.
3. Place the valve spring in position over the valve and install the valve spring retainer.
4. Using the special tools, compress the valve spring and install the valve spring retainer keys. Remove the special tools.
5. Install the CHT sensor.
6. Install the front lifting eye.
7. Install the rear lifting eye.
8. Install the bracket.
9. Install the inner timing belt cover.
10. Install the timing belt tensioner and pulley.
11. Install the exhaust manifold.
12. Install the intake manifold.
13. Install the ignition coil bracket.
14. Install the camshaft sensor.

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1. Use the Piston Pin Tool to press the piston pin out from the piston assembly and connecting rod.
2. Remove the connecting rod and piston rings from the piston.
3. Clean and inspect the piston, piston pin and connecting rod. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-204610) .

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1. Lubricate the piston pin and piston pin bore. Use Super Premium SAE 5W-20 Motor Oil or equivalent meeting Ford specification WSS-M2C153-H.
2. Position the piston pin in the bore aligned with the connecting rod bore.
3. Use the Piston Pin Tool to press the piston pin into the piston and connecting rod assembly.
4. Fit and install the piston rings. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-204610) .

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1. Carefully clean and dry the cylinder block. Clean gasket material, dirt and foreign material from the cylinder block. Wash the cylinder block with a suitable soap and water solution. Dry the cylinder block completely using compressed air.
2. Install the Woodruff key.
3. Install the upper crankshaft main bearings, the upper crankshaft thrust main bearing and the lower crankshaft main bearings.
4. Position the crankshaft.
5. Determine crankshaft main bearing clearance. For additional information, refer to Select Fit Method in «ENGINE SYSTEM-GENERAL INFORMATION»(ref-204610) .
6. Install the main bearing caps.
7. Tighten the bolts using the sequence shown in two stages. Stage 1: Tighten the bolts to 25 Nm (18 lb-ft). Stage 2: Tighten the bolts an additional 60 degrees.
8. Rotate the crankshaft and inspect for excessive drag or binding.
9. Inspect the crankshaft end play. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-204610) .
10. Using the special tools, install the four piston and connecting rod assemblies.
11. Fit the connecting rod bearing. Install the four upper and the four lower connecting rod bearings. Inspect the connecting rod bearing to the crankshaft clearance. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-204610) .
12. Install the connecting rod caps. Install new bolts and tighten in two stages: Stage 1: Tighten to 35 Nm (26 lb-ft). Stage 2: Tighten an additional 90 degrees.
13. Install a new gasket, the crankshaft rear oil seal retainer and tighten the bolts in two stages: Stage 1: Tighten to 12 Nm (9 lb-ft). Stage 2: Tighten an additional 45 degrees.
14. Install a new gasket, the oil pump and tighten the bolts in two stages: Stage 1: Tighten to 6 Nm (53 lb-in). Stage 2: Tighten an additional 45 degrees.
15. Using the special tool, install a new crankshaft front seal.
16. Install a gasket and the lower cylinder block. Tighten the bolts using the sequence shown.
17. Install the oil pump cover and screen. Install new oil pump inlet tube gasket.
18. Install the oil pan. Tighten the bolts in two stages using the sequence shown. Stage 1: Tighten to 6 Nm (53 lb-in). Stage 2: Tighten to 12 Nm (9 lb-ft).
19. Install a new head gasket on the cylinder block.
20. Install the cylinder head and tighten the bolts in three stages using the sequence shown. Stage 1: Tighten the bolts to 20 Nm (15 lb-ft). Stage 2: Tighten the bolts to 40 Nm (30 lb-ft). Stage 3: Tighten the bolts an additional 90 degrees.
21. Install the timing belt guide and crankshaft sprocket.
22. Install the oil cooler. Install a new oil cooler gasket.
23. Install the knock sensor.
24. Install the block heater if equipped.
25. Install the oil pressure sensor.
26. Install the intake manifold and tighten using the sequence shown.
27. Install the positive crankcase ventilation (PCV) tube.
28. Install the thermostat housing. Install a new O-ring seal if damaged.
29. Install the coil and coil bracket assembly.
30. Install the exhaust gas recirculation (EGR) tube.
31. Connect the EGR tube fitting.
32. Install the fuel charging wiring harness and connect the following electrical connectors: cylinder temperature sensor Throttle position sensor Wiring harness to vehicle Idle air control valve Camshaft position sensor fuel injectors
33. Install the generator bracket.
34. Install the generator.
35. Install the inner timing belt cover.
36. Loosely install the crankshaft pulley and rotate the crankshaft to just before top dead center (TDC) (No. 1 cylinder).
37. Remove the stud.
38. Install the special tool.
39. Rotate the crankshaft clockwise against the peg to bring it to TDC (No. 1 cylinder). Remove the crankshaft pulley.
40. Install the valve tappets.
41. Install the camshafts. Position the camshafts and camshaft journal caps. Install the bolts and tighten the bolts in several two-turn passes using the sequence shown.
42. Coat the sealing surface of the front camshaft journal cap with Gasket Maker F8AZ-19B508-AB or equivalent meeting Ford specification WSK-M2G348-A5.
43. Using the special tool, install new camshaft front oil seals.
44. Install the camshaft sprockets and hand tighten the bolts. Rotate the camshafts one full turn and inspect them for binding.
45. Verify the valve clearance. For additional information, refer to «VALVE - VALVE CLEARANCE, ADJUST»(ref-204616-S39668227222005111200000) .
46. Install the special tool onto the back of the camshafts.
47. Loosen the timing sprocket bolts and allow the camshaft sprockets to move freely.
48. Install the timing belt idler pulley.
49. Install the coolant pump adapter. Install a new gasket.
50. Slide the crankshaft pulley onto the crankshaft and confirm the crankshaft position is at TDC (No. 1 cylinder) by rotating it clockwise against the alignment peg. Remove the crankshaft pulley.
51. Position a new timing belt in place. Starting from the crankshaft timing belt pulley and working counterclockwise, position the timing belt in place while keeping it under tension.
52. Pre-tension the timing belt. Rotate the tensioner locating tab counterclockwise and insert the locating tab into the slot in the rear timing cover. Position the hex key slot in the tensioner adjusting washer to the 4 o'clock position. Tighten the attaching bolt enough to seat the tensioner firmly against the rear timing cover, but still allow the tensioner adjusting washer to be rotated using a 6 mm hex key.
53. Using the hex key, rotate the adjusting washer counterclockwise until the notch in the pointer is centered over the index line on the locating tab (the pointer will move clockwise during adjustment).
54. While holding the adjusting washer in position, tighten the bolt.
55. Tighten the bolt on the intake camshaft sprocket.
56. Tighten the bolt on the exhaust camshaft sprocket in three stages. Stage 1: Tighten the bolt to 50 Nm (36 lb-ft). Stage 2: Remove the TDC peg and the camshaft alignment timing tool. Stage 3: Tighten the bolt to 115-125 Nm (85-92 lb-ft).
57. Screw in the new oil plug on the variable camshaft timing assembly.
58. Check the valve timing by inserting the special tools and correct the alignment as necessary. Screw in special tool 303-574 and make sure that the crankshaft is resting against the special tool. Insert special tool 303-465 into the camshafts. If necessary loosen the timing pulleys and correct the camshaft alignment. Remove the special tools.
59. Install the bolts and the valve cover. Install the valve cover gasket.
60. Position and connect the wiring harness.
61. Connect the ignition wires to the correct spark plugs.
62. Install the timing belt upper cover.
63. Position the wire harness.
64. Install the lower engine mount bracket.
65. Install the coolant pump pulley.
66. Install the lower timing belt cover.
67. Install the accessory drive belt idler pulley.
68. Install the crankshaft pulley.
69. Install the coolant tube. Install the bolt. Connect the hose.
70. Install the crankcase vent oil separator. Install the bolts. Install a new gasket. Connect the PCV valve.
71. Install the crankshaft position sensor and bushing.
72. Install the stud.
73. Install the coolant tube. Install the bolt and nut. Connect the hose.
74. Install the A/C compressor bracket.
75. Install the power steering pump bracket.
76. Install the exhaust manifold and tighten using the sequence shown. Install a new gasket.
77. Install the oil level indicator and tube. Install a new O-ring seal if damaged.
78. Support the engine with a suitable lifting device and remove the engine from the engine stand.
79. Install the rear cover plate and dowels.
80. Using the special tools, install a new crankshaft rear seal.
81. Using the special tools, install the pilot bearing.
82. Install the flywheel.
83. Install flywheel holding tool.
84. Using the special tool, position the clutch disc onto the flywheel.
85. Position the clutch pressure plate onto the flywheel, install the pressure plate bolts and tighten them using the sequence shown.

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1. Install the transaxle on the engine and install the bolts.
2. Install the bolts.
3. Install the starter and the bolts.
4. Install the starter wiring harness.
5. Install the engine wiring harness. Attach the wiring harness to the engine/transaxle assembly. Connect the differential pressure feedback exhaust gas recirculation (EGR) system electrical connector.
6. Connect the ignition coil electrical connector.
7. Connect the reversing lamp switch electrical connector.
8. Connect the ground wire.
9. Connect the powertrain control module (PCM) wiring harness to the bracket.
10. Connect the fuel charging wiring harness electrical connector.
11. Install the ground wire and the bolt on the bell housing.
12. Connect the crankshaft position (CKP) sensor electrical connector.
13. Connect the vehicle speed sensor electrical connector.
14. Connect the electrical connectors. Connect the knock sensor electrical connector. Connect the oil pressure sender electrical connector. Connect the starter electrical connector.
15. Connect the generator electrical connectors.
16. Position the engine/transaxle assembly into the vehicle.
17. Install the LH transaxle mount.
18. Install the engine mount upper bracket.
19. Connect the ground wire.
20. Install the front transaxle support insulator and bracket. Position the front transaxle support insulator. Install the four transaxle support insulator bracket bolts. Loosely install the front transaxle support insulator bolt.
21. Install the rear transaxle mount.
22. Remove the lifting device.
23. Install the speed control unit (if equipped).
24. Position the power steering pump and loosely install the upper bolts.
25. Install the power steering hose bracket bolt.
26. Install the power steering hose bracket bolt.
27. Position the slave cylinder line and install the clip.
28. Install the clutch slave cylinder bolts.
29. Position the power steering hoses and install the bolts.
30. Raise and support the vehicle. .
31. Install the lower power steering bolts.
32. Connect the power steering pressure sensor electrical connector.
33. Connect the lower radiator hose.
34. Install the engine to transaxle bolts.
35. Install the intermediate shaft and the bracket as an assembly. 4x4 vehicles
36. Install the transfer case. For additional information, refer to «TRANSFER CASE»(ref-194831) . All vehicles
37. Install a new oil filter.
38. Install the front transaxle mount through bolt.
39. Connect the block heater electrical connector. 4x2 vehicles
40. Connect the shifter linkages. All vehicles
41. Install the driveshafts.
42. Using the special tool, position the halfshaft into the front wheel knuckle.
43. Install the lower control arm and the ball joint pinch bolt and nut.
44. Loosely install new front axle wheel hub nuts.
45. Install the A/C compressor.
46. Install the A/C manifold and tube assembly bolt.
47. Connect the A/C clutch field coil electrical connector.
48. Rotate the accessory drive belt tensioner clockwise and install the belt.
49. Connect the coolant hose.
50. Install the engine/convertor bracket.
51. Install the catalytic convertor. .
52. Connect the coolant hose.
53. Install the splash shield and bolts.
54. Clean the wheel hub mounting surface and wheel pilot.
55. Install the tire and wheel assembly. Position the tire and wheel assembly. Install the wheel nuts hand-tight, then lower the vehicle.
56. Tighten the wheel nuts in the sequence shown.
57. Tighten the LH and RH axle hub nuts.
58. Install the center cap.
59. Connect the heater hoses.
60. Tighten the upper power steering pump bolts to specification.
61. Connect the upper radiator hose.
62. Connect the evaporative emission (EVAP) canister vacuum lines.
63. Connect the power distribution box electrical connections.
64. Connect the wire harness electrical connector.
65. Connect the ground wire.
66. Connect the powertrain control module (PCM) wire harness and ground.
67. Connect the brake booster vacuum supply hose to the intake manifold.
68. Connect the EGR vacuum regulator valve. Connect the electrical connector. Connect the vacuum hoses.
69. Connect the throttle cables and, if equipped, speed control cable.
70. Connect the fuel hose. 4x4 vehicles
71. Install the shifter cables. Install the cables into the brackets. Position the shifter cables onto the shifter levers and install the clips. All vehicles
72. Install the air cleaner (ACL) and outlet pipe. Position the ACL and outlet pipe as an assembly in the vehicle. Install the bolt. Connect the mass air flow sensor electrical connector.
73. Connect the air cleaner outlet tube. Connect the outlet tube to the throttle body. Tighten the clamp. Connect the crankcase ventilation hose. Attach the emission tube and hose. Attach the accelerator cable.
74. Install the accelerator control cable support bracket bolt.
75. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204629) .
76. Fill the engine with Super Premium SAE 5W-20 Motor Oil or equivalent meeting Ford specification WSS-M2CH153-H.
77. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-204619) .
78. Charge the A/C system. For additional information, refer to «MANUAL A/C-HEATER SYSTEMS»(ref-139311) .
79. Fill the transaxle fluid. For additional information, refer to «MANUAL TRANSAXLE/TRANSMISSION AND CLUTCH - GENERAL INFORMATION»(ref-204621) . 4x4 vehicles
80. Adjust the gear shift cables. For additional information, refer to «MANUAL TRANSAXLE/TRANSMISSION AND CLUTCH - GENERAL INFORMATION»(ref-204621) . All vehicles
81. Install the hood. Connect the washer hose. Install the bolts.