Engine - 3.0L (4V): Removal & Installation Ford Escape I

Installation

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1. Clean all sealing surfaces with metal surface cleaner.
2. Install 3 new gaskets in the front cover.
3. Apply a 6 mm (0.24 in) diameter dot of silicone gasket and sealer to the cylinder block, lower cylinder block, cylinder head and oil pan mating surfaces.
4. Position the cover and install the studs and bolts in the sequence shown.
5. Install the 2 oil pan-to-front cover bolts. Tighten to 25 Nm (18 lb-ft).
6. Remove the oil pan plug and drain the engine oil. Install the plug and tighten to 26 Nm (19 lb-ft).
7. Install the (CKP) sensor and connect the electrical connector.
8. Install the crankshaft front seal. For additional information, refer to «CRANKSHAFT FRONT OIL SEAL»(ref-204613-S16922465532005111200000) .
9. Install the tensioner and bolt.
10. Install the power steering pump. For additional information, refer to «POWER STEERING»(ref-204590) .
11. Install the CMP and the bolt. Connect the electrical connector.
12. Install the generator bracket and bolts.
13. Position the generator and install the lower generator bolts.
14. Install the upper generator bolts.
15. Position the wiring harness and bracket and install the nut.
16. Rotate the accessory drive belt tensioner clockwise and install the accessory drive belt.
17. Install the splash shield and the screws and pin-type retainer.
18. Install the RH and LH valve cover. For additional information, refer to «VALVE COVER RH»(ref-204613-S37859176532005111200000) and «VALVE COVER LH»(ref-204613-S27429627872005111200000) removal.
19. Fill the engine with clean engine oil.
20. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204629) .
21. Fill and bleed the power steering system. For additional information, refer to «STEERING SYSTEM - GENERAL INFORMATION»(ref-204578) .

Removal

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1. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-204613-S17100950192005111200000) .
2. Remove the ignition pulse wheel.
3. Install the damper bolt.
4. Remove the LH and the RH spark plugs.
5. Rotate the crankshaft clockwise to position the crankshaft keyway in the 11 o'clock position and position the camshafts in the correct position. This will position the number 1 cylinder at top dead center (TDC). Verify that the camshafts are correctly located. If not, rotate the crankshaft one additional turn and recheck.
6. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to locate the RH camshafts in the neutral position.
7. Verify that the RH camshafts are in the neutral position.
8. Remove the RH timing chain and tensioner arm. Remove the bolts. Remove the tensioner. Remove the tensioner arm.
9. Remove the bolts, RH timing chain guide and the timing chain.
10. Rotate the crankshaft clockwise 600 degrees (1-2/3 times) to position the crankshaft keyway in the 11 o'clock position. This will position the LH camshafts in the neutral position.
11. Verify that the LH camshafts are in the neutral position.
12. Remove the LH timing chain and tensioner arm. Remove the bolts. Remove the tensioner. Remove the tensioner arm.
13. Remove the LH timing chain and the timing chain guide.
14. Remove the damper bolt and the crankshaft sprockets.

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1. Install the crankshaft sprockets.
2. Position the chain tensioner in a soft-jawed vise.
3. Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
4. Slowly compress the timing chain tensioner.
5. Retain the tensioner piston with a 1.5 mm (0.06 in) wire or paper clip.
6. If the timing marks on the timing chains are not evident, use a permanent-type marker to mark on the LH and the RH timing chains. Mark any link to use as the crankshaft timing mark. Starting with the crankshaft timing mark, count 29 links and mark the link. Continue counting to 42 and mark the link.
7. Position the LH timing chain and guide and install the bolts. Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
8. Install the LH timing chain tensioner and tensioner arm. Install the tensioner arm. Position the tensioner. Install the bolts.
9. Install the crankshaft damper bolt and rotate the crankshaft clockwise 120 degrees until the crankshaft keyway is in the 3 o'clock position.
10. Verify that the RH camshafts are correctly positioned.
11. Position the RH timing chain and chain guide and install the bolts. Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
12. Install the RH timing chain tensioner and tensioner arm. Install the tensioner arm. Position the tensioner. Install the bolts.
13. Remove the LH and RH timing chain tensioner piston retaining wires.
14. Rotate the crankshaft counterclockwise 120 degrees to top dead center (TDC).
15. Verify the timing with the following steps. There should be 12 chain links between the front camshaft timing marks. There should be 27 chain links between the camshaft and crankshaft timing marks. There should be 30 chain links between the camshaft and crankshaft timing marks.
16. Remove the crankshaft damper bolt.
17. Install the LH and RH spark plugs.
18. Install the ignition pulse wheel.
19. Install the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-204613-S17100950192005111200000) .

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Removal and Installation

1. Remove the camshaft followers. For additional information, refer to «ROLLER FOLLOWERS»(ref-204613-S37592917832005111200000) .
2. Remove the hydraulic lash adjusters.
3. To install, reverse the removal procedure. Lubricate the hydraulic lash adjusters with clean engine oil.

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1. Remove the valve spring. Refer to «VALVE SPRING»(ref-204613-S21127114982005111200000) .
2. Remove the valve seal.

Note. Lubricate the valve guide with clean engine oil.

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1. Using the special tool, install the valve seal.
2. Install the valve spring. Refer to «VALVE SPRING»(ref-204613-S21127114982005111200000) .

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1. Remove the LH heated oxygen sensor (HO2S) and the LH catalyst monitor. For additional information, refer to «REMOVAL, OVERHAUL & INSTALLATION»(ref-142374) .
2. Remove the bolts and the splash shield.
3. Remove the nuts and position the exhaust crossover aside.
4. Rotate the accessory drive belt tensioner clockwise, and remove the belt.
5. Remove the A/C compressor bolts and position aside.
6. Remove the nuts and LH exhaust manifold and discard the gasket.

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1. Position a new gasket and tighten the exhaust manifold in the sequence shown.
2. Position the A/C compressor and install the bolts.
3. Rotate the accessory drive belt tensioner clockwise and install the belt. For correct drive belt installation, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-139084) .
4. Position the exhaust crossover, and install the nuts.
5. Install the splash shield.
6. Install the LH HO2S and the LH catalyst monitor. For additional information, refer to «REMOVAL, OVERHAUL & INSTALLATION»(ref-142374) .

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1. Remove the generator. For additional information, refer to «GENERATORS & REGULATORS»(ref-139334) .
2. Remove the exhaust flexible pipe.
3. Disconnect the RH heated oxygen sensor (HO2S) electrical connector.
4. Disconnect the exhaust gas recirculation (EGR) tube nut to the exhaust manifold.
5. Remove the RH manifold. Discard the gasket.

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1. Position a new gasket and install the exhaust manifold nuts in the sequence shown.
2. Connect the EGR tube nut to the exhaust manifold.
3. Connect the RH HO2S electrical connector.
4. Install the exhaust flexible pipe. .
5. Install the generator. For additional information, refer to «GENERATORS & REGULATORS»(ref-139334) .

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1. Clean all sealing surfaces on the engine and the oil pan with metal surface cleaner.
2. Position a new gasket on the oil pan.
3. Apply a 10 mm (0.40 in) diameter dot of silicone gasket and sealer to the areas indicated.
4. Position the oil pan and gasket and loosely install the bolts in the sequence shown.
5. Install the oil pan-to-transaxle bolts.
6. Tighten the oil pan bolts in the sequence shown.
7. Lubricate the oil filter O-ring with clean engine oil and install the oil filter.
8. Install the exhaust flexible exhaust pipe. .
9. Connect the downstream catalyst monitor.
10. Lower the vehicle.
11. Fill the crankcase with clean engine oil.

1. Using the special tools, install the crankshaft rear oil seal.
2. Install the flexplate. For additional information, refer to «FLEXPLATE»(ref-204613-S42198822162005111200000) .

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1. Remove the engine ground wire.
2. Using the special tools, support the engine.
3. Remove the A/C line bracket bolt and position the A/C lines out of the way.
4. Remove the engine support insulator bolt.
5. Remove the engine support insulator. Remove the nut. Remove the bolts and insulator.
6. To install, reverse the removal procedure.

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1. Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-204629) .
2. Remove the air cleaner outlet pipe and air cleaner. .
3. Recover the A/C refrigerant. For additional information, refer to «MANUAL A/C-HEATER SYSTEMS»(ref-139311) .
4. Raise and support the vehicle. .
5. Remove the lower radiator air deflectors.
6. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-204619) .
7. Drain the engine oil. Install the drain plug.
8. Lower the vehicle.
9. Disconnect the fuel hose spring lock coupling.
10. Remove the water pump drive belt. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-139084) .
11. Disconnect the accelerator cable and, if equipped, the speed control actuator cable.
12. Disconnect the vapor management valve (VMV) connectors.
13. Disconnect the powertrain control module (PCM) electrical connector.
14. Disconnect the ground wire.
15. Disconnect the hoses.
16. Remove the tie-strap and disconnect the heater hose.
17. Disconnect the electrical connector from the power distribution box.
18. Remove the power distribution box cover.
19. Remove the nuts and the cables.
20. Disconnect the transaxle linkage.
21. Disconnect the brake booster vacuum hose.
22. Disconnect the vacuum hose at the vacuum reservoir check valve.
23. Disconnect the power steering return tube.
24. Disconnect the power steering hose. Disconnect the power steering pressure (PSP) switch electrical connector. Remove the bracket bolt. Disconnect the power steering hose.
25. Remove the oil level indicator.
26. Disconnect the ground strap and the connector.
27. Remove the wiring harness retainers and position the wiring harness out of the way.
28. Remove the flex pipe.
29. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt.
30. If equipped, disconnect the engine block heater electrical connector.
31. Disconnect the A/C clutch field coil electrical connector.
32. Remove the A/C manifold and tube assembly bolt from the top of the A/C compressor and disconnect the A/C manifold and tube assembly.
33. Remove the bolts and the A/C compressor.
34. Remove both front wheel and tire assemblies.
35. If equipped, remove the intermediate driveshaft. For additional information, refer to «DRIVESHAFT»(ref-204573) .
36. Separate the LH and RH stabilizer bar links from the strut mount.
37. If equipped, remove the bolt and position aside the LH and RH wheel speed sensors.
38. If equipped, remove the LH and RH wheel speed sensor brackets.
39. Remove the LH and RH brake calipers from the steering knuckles and support them on the struts.
40. Remove the nuts and bolts and separate the struts from the LH and RH steering knuckles.
41. Remove the bolt and separate the steering shaft from the rack.
42. Disconnect the two transmission cooler tubes.
43. Remove the torque converter inspection cover.
44. Remove the four torque converter nuts.
45. Remove the four bolts.
46. Position the universal powertrain lift.
47. Using a bracket from a heavy-duty engine stand, support the front of the engine.
48. Remove the bolts and the nuts, remove the engine support bracket.
49. Disconnect the power steering return hose.
50. Remove the bolts and the transaxle support.
51. Remove two rear subframe bolts.
52. Remove the two subframe side nuts.
53. Remove the two bolts from the motor mount support.
54. Remove the powertrain from the vehicle.
55. Disconnect the heated oxygen sensor electrical connectors.
56. Disconnect the transmission range (TR) sensor electrical connector.
57. Disconnect the transaxle wiring harness electronic control switch electrical connector.
58. Remove the bolt and separate the transaxle control harness from the bracket.
59. Remove the two bolts, the starter and the wiring harness as an assembly.
60. Disconnect the knock sensor jumper electrical connector.
61. Disconnect the output shaft speed (OSS) sensor and the turbine speed sensor (TSS) electrical connectors.
62. Remove the tie-strap and disconnect the HO2S sensor.
63. Disconnect the differential pressure feedback EGR system electrical connector.
64. Disconnect the EGR tube nut at the manifold connector.
65. Disconnect the EGR tube fitting and remove the EGR tube.
66. Remove the generator. Disconnect the electrical connector. Remove the bolts.
67. Remove the six RH exhaust manifold nuts and the gasket.
68. Remove the bolts and position the halfshaft support bracket out of the way.
69. Using the special tools, remove the powertrain from the universal powertrain lift.
70. Remove the six transaxle bolts.
71. Using the special tools, remove the engine from the transaxle.

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1. Separate the engine control sensor wiring connectors from the upper intake manifold.
2. Disconnect the idle air control valve and the throttle position sensor.
3. Disconnect the exhaust gas recirculation (EGR) vacuum regulator and the differential pressure feedback EGR electrical connectors.
4. Remove the positive crankcase ventilation (PCV) tube.
5. Disconnect the vacuum line from the fuel pressure regulator.
6. Disconnect and remove the engine control wire harness.
7. Remove the bolts and upper intake manifold.
8. Disconnect the crankshaft and camshaft position sensors.
9. Disconnect the radio ignition interference capacitor.
10. Disconnect the remaining electrical connectors and harness retainers and remove the harness. coils-on-plugs fuel injectors
11. Remove the bolts and the six coil-on-plugs.
12. Disconnect the coolant temperature sensor and the oil pressure switch.
13. Remove the fuel charging wire harness.
14. Remove the lower intake manifold.
15. Remove the radio interference capacitor. Remove the nut.
16. Remove the RH valve cover. Remove and discard the gasket if damaged.
17. Remove the engine lift bracket.
18. Remove the LH exhaust manifold.
19. Remove the RH exhaust manifold.
20. Remove the knock sensor.
21. Remove the LH valve cover. Remove and discard the gasket.
22. Disconnect the hoses.
23. Remove the water pump assembly.
24. Disconnect the coolant hoses at the oil cooler.
25. Remove the bolt.
26. Using the special tool, remove the crankshaft damper.
27. Remove the power steering pump pulley.
28. Remove the oil filter.
29. Remove the power steering pump.
30. Remove the generator support bracket.
31. Remove the oil cooler.
32. Remove the oil pressure sender and the block heater.
33. Remove the bolts and studs and the oil pan. Discard the gasket.
34. Remove the bolts, nut and the oil pick up tube and screen.
35. Remove the nuts and the oil pan baffle.
36. Remove the stud and the oil level indicator and tube.
37. Clean all sealing surfaces with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A. Remove the bolts, studs, and the front cover. Discard the gasket.
38. Remove the crankshaft front seal from the front cover.
39. Remove the ignition pulse wheel.
40. Install the damper bolt.
41. Remove the LH and RH spark plugs.
42. Rotate the crankshaft clockwise to position the crankshaft keyway in the 11 o'clock position and position the camshafts in the correct position. This will position the number one cylinder at top dead center (TDC). Verify that the camshafts are correctly located. If not, rotate the crankshaft one additional turn and recheck.
43. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to locate the RH camshafts in the neutral position.
44. Verify that the RH camshafts are correctly positioned.
45. Remove the RH timing chain tensioner arm. Remove the bolts. Remove the tensioner. Remove the tensioner arm.
46. Remove the bolts, RH timing chain guide and the timing chain.
47. Rotate the crankshaft clockwise 600 degrees (1-2/3 times) to position the crankshaft keyway in the 11 o'clock position. This will position the LH camshafts in the neutral position.
48. Verify the LH camshafts are in the neutral position.
49. Remove the LH timing chain and tensioner arm. Remove the bolts. Remove the tensioner. Remove the tensioner arm.
50. Remove the LH timing chain and timing chain guide.
51. Remove the damper bolt and the crankshaft sprockets.
52. Loosen the LH and RH camshaft cap bolts in the indicated sequence and remove the camshaft caps. Tap the caps lightly with a soft-faced mallet to loosen the camshaft caps.
53. Remove the LH and RH camshafts.
54. Remove the LH and RH camshaft followers. Mark the location of the followers using a permanent-type marker.
55. Remove the coolant by pass tube.
56. Loosen the bolts in the indicated sequence and remove the LH and RH cylinder heads. Discard the gaskets.
57. Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge and feeler gauge. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area, or scratches more than 0.0254 mm (0.001 in) deep.
58. Remove the power steering/engine support bracket.
59. Remove the oil separator.
60. Remove the bolts in the indicated sequence and remove the oil pump.
61. Using the special tool, remove the cylinder ridge.
62. Remove the connecting rod cap bolts. Hold the piston/rod assembly to keep it from falling from the engine block.
63. Using the special tool, remove the piston/rod assembly from the engine block. Remove the connecting rod bearings.
64. Remove the engine block from the stand and place it on a workbench.
65. Remove the bolts and the flexplate.
66. Remove the bolts and studs in the indicated sequence and remove the lower cylinder block.
67. Remove the crankshaft rear main seal and remove the crankshaft.
68. Remove the crankshaft key.
69. Remove the crankshaft thrust bearing from the cylinder block.
70. Remove the bearings from the lower cylinder block.
71. Remove the crankshaft main bearings from the cylinder block.
72. Inspect the cylinder block, lower cylinder block, pistons and connecting rods. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-204610) for basic mechanical concerns.

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