Engine - 2.3L - (Hybrid): Overhaul Ford Escape I рестайлинг

Disassembly

1. Remove the 2 bolts and the exhaust gas recirculation (EGR) valve. Discard the gasket.
2. Remove the 4 bolts and the coolant outlet. Discard the gasket.
3. Remove and discard the cylinder head temperature (CHT) sensor.
4. Remove the spark plugs.
5. Remove the valve tappets.
6. Using the special tools, compress the valve springs and remove the valve collets, valve spring retainers and the valve springs.
7. Inspect the components, if necessary. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-232214) .
8. Remove the valves.
9. Using the special tools, remove and discard the valve seals.
10. Inspect the valves. For additional information, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(ref-232214) . Install new parts, as necessary.

Assembly

1. Install the valves.
2. Using the special tool, install the valve seals.
3. Using the special tools, install the valve springs. Insert the valve springs and the valve spring retainers. Compress the valve springs and install the valve collets, using grease and a small screwdriver.
4. Install the valve tappets.
5. Install the spark plugs. Tighten to 15 Nm (11 lb-ft).
6. Install a new CHT sensor. Tighten to 12 Nm (9 lb-ft).
7. Using a new gasket, install the coolant outlet and bolts. Tighten to 25 Nm (18 lb-ft).
8. Install the EGR valve, using a new gasket. Tighten to 25 Nm (18 lb-ft).

SPECIAL TOOL(S) DESCRIPTION Heavy Duty Floor Crane 014-00071 or equivalent Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Alignment Plate, Camshaft 303 - 465 (T94P-6256-CH) Timing Peg, Crankshaft 303 - 507 Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A) Adapter for 205-126 (205-072-02) Installer, Front Oil Seal 303-096 (T74P-6150-A) Installer, Crankshaft Rear Main Oil Seal 303 - 328 (T88P-6701-B1)

MATERIALS

Scheme 473

Scheme 474

Scheme 475

Scheme 476

Scheme 477

Scheme 478

Scheme 479

Scheme 480

Scheme 481

Scheme 482

Scheme 483

Scheme 484

Scheme 485

Scheme 486

Scheme 487

Scheme 488

Scheme 489

Scheme 490

Scheme 491

1. Turn the crankshaft clockwise to position the No. 1 piston at TDC.
2. Remove the engine plug bolt.
3. Install the special tool.
4. Install the block-off plate and bolts. Tighten to 25 Nm (18 lb-ft).
5. Install the oil pump assembly. Tighten the bolts in the sequence see scheme 215in the following 2 stages: Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten to 20 Nm (15 lb-ft).
6. Install a new oil pump pickup tube gasket and the pickup tube. Tighten to 10 Nm (89 lb-in).
7. Using the special tool, install the crankshaft rear main oil seal.
8. Tighten the crankshaft rear main oil seal bolts in the sequence see scheme 218 Tighten to 10 Nm (89 lb-in).
9. Clean and inspect all mating surfaces.
10. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan. Install the oil pan. Install the 2 oil pan bolts finger-tight.
11. Install the remaining oil pan bolts and tighten the oil pan bolts in the sequence see scheme 220 Tighten to 25 Nm (18 lb-ft).
12. Install the cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.
13. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block. Remove any large deposits of silicone or gasket material with a plastic scraper. Apply silicone gasket remover, following package directions, and allow to set for several minutes. 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. 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.
14. Apply silicone gasket and sealant to the locations shown see scheme 222.
15. Install a new head gasket.
16. Install new cylinder head bolts. Tighten the bolts in the sequence (Scheme 478)in the following 5 stages: Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten to 15 Nm (11 lb-ft). Stage 3: Tighten to 45 Nm (33 lb-ft). Stage 4: Turn 90 degrees. Stage 5: Turn an additional 90 degrees.
17. Install the camshafts and bearing caps. Tighten the bolts in the sequence see scheme 225in the following 3 stages: Stage 1: Tighten 1 turn at a time until tight. Stage 2: Tighten to 7 Nm (62 lb-in). Stage 3: Tighten to 16 Nm (12 lb-ft).
18. Install the crankshaft sprocket, crankshaft sprocket diamond washers, oil pump chain and oil pump sprocket. The crankshaft sprocket flange must be facing away from the engine block.
19. Install the oil pump chain, sprocket and bolt. Tighten to 25 Nm (18 lb-ft).
20. Install the oil pump chain guide and the shoulder bolts. Tighten to 10 Nm (89 lb-in).
21. Install the oil pump chain tensioner. Hook the tensioner spring around the shoulder bolt. Tighten to 10 Nm (89 lb-in).
22. Install the special tool in the slots on the rear of both camshafts.
23. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.
24. Install the LH timing chain guide and the bolts. Tighten to 10 Nm (89 lb-in).
25. Install the timing chain.
26. Install the RH timing chain guide.
27. Using the edge of a vise, compress the timing chain tensioner plunger.
28. Using a small pick, push back and hold the ratchet mechanism.
29. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
30. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
31. Install the timing chain tensioner and the bolts. Remove the paper clip to release the piston. Tighten to 10 Nm (89 lb-in).
32. Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts. Tighten to 65 Nm (48 lb-ft).
33. Clean and inspect the mounting surfaces of the engine and the front cover.
34. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the front cover.
35. Install the engine front cover. Tighten the bolts in the sequence (Scheme 488), to the following specifications: Tighten the 8-mm bolts to 10 Nm (89 lb-in). Tighten the 13-mm bolts to 48 Nm (35 lb-ft).
36. Using the special tool, install the crankshaft front oil seal.
37. Install the crankshaft pulley and hand-tighten the bolt.
38. Install a standard 6 mm (0.23 in) x 18 mm (0.7 in) bolt through the crankshaft pulley and thread it into the front cover. Rotate the pulley as necessary to align the bolt holes.
39. Using the special tools to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages: Stage 1: Tighten to 100 Nm (74 lb-ft). Stage 2: Tighten an additional 90 degrees (1/4 turn).
40. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
41. Remove the special tool.
42. Remove the special tool.
43. Turn the engine 2 complete revolutions.
44. Turn the crankshaft until the No. 1 piston is at TDC.
45. Install the special tool.
46. Using the 6 mm (0.23 in) x 18 mm (0.7 in) bolt, check the position of the crankshaft pulley. If it is not possible to install the bolt, correct the engine timing.
47. Using the special tool, check the position of the camshafts. If it is not possible to install the special tool, correct the engine timing.
48. Install the crankshaft position (CKP) sensor. Do not tighten the bolts at this time.
49. Adjust the CKP sensor alignment jig and tighten the bolts. Tighten to 7 Nm (62 lb-in).
50. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
51. Install the engine plug bolt. Tighten to 20 Nm (15 lb-ft).
52. Clean the valve cover gasket surface with metal surface cleaner.
53. Apply silicone gasket and sealant to the locations see scheme 256
54. Install the valve cover. Tighten the bolts in the sequence see scheme 257to 10 Nm (89 lb-in).
55. Install a new cylinder head temperature (CHT) sensor and the spark plugs. Tighten the CHT sensor to 12 Nm (9 lb-ft). Tighten the spark plugs to 15 Nm (11 lb-ft).
56. Install the coil-on-plugs, bolts and the crankcase vent tube. Tighten to 10 Nm (89 lb-in).
57. Install the 3 engine cover studs.
58. If equipped, install the block heater. Tighten to 21 Nm (15 lb-ft).
59. Install the coolant hoses.
60. Install the oil filter adapter with a new gasket. Tighten to 25 Nm (18 lb-ft).
61. Install the crankcase vent oil separator and the KS. Tighten the oil separator bolts to 10 Nm (89 lb-in). Tighten the KS to 20 Nm (15 lb-ft).
62. Install the coolant hose.
63. Install the thermostat housing. Tighten to 10 Nm (89 lb-in).
64. Install the coolant hose.
65. Install the coolant pump and bolts. Tighten to 10 Nm (89 lb-in).
66. Install the coolant pump pulley and bolts. Tighten to 20 Nm (15 lb-ft).
67. Position the engine control wiring harness on the engine and connect the exhaust gas recirculation (EGR) valve electrical connector.
68. Connect the radio ignition interference capacitor electrical connector.
69. If equipped, connect the block heater electrical connector.
70. Connect the CHT sensor and install the rubber boot.
71. Connect the coil-on-plug and camshaft position (CMP) sensor electrical connectors.
72. Install the accessory drive belt tensioner. Tighten to 25 Nm (18 lb-ft).
73. Attach the engine wiring harness pin-type retainer.
74. Install the engine wiring harness connector bracket. Tighten to 15 Nm (11 lb-ft).
75. Connect the CKP sensor electrical connector.
76. Using the heavy duty floor crane and spreader bar, remove the engine from the engine stand.
77. Install the flywheel and the bolts. Tighten the bolts in the sequence see scheme 278in the following 3 stages: Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Tighten to 80 Nm (59 lb-ft). Stage 3: Tighten to 112 Nm (83 lb-ft).

SPECIAL TOOL(S) DESCRIPTION Heavy Duty Floor Crane 014-00071 or equivalent Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Powertrain Lift (014-00765) Universal Adapter Brackets 014-0001 Lifting Bracket Set, Engine 303-D095 (D94L-6001-A) or equivalent

MATERIALS

Scheme 492

Scheme 493

Scheme 494

Scheme 495

Scheme 496

1. Install the transaxle damper. Tighten to 29 Nm (21 lb-ft).
2. Using the engine crane and spreader bar, position the engine and transaxle together. Install the 6 transaxle-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
3. Position the high voltage wiring harness and connect the 2 transaxle electrical connectors.
4. Connect the high voltage wiring harness electrical connector.
5. Using the engine crane and spreader bar, position the engine and transaxle onto the lift table.
6. Using the special tools, secure the engine to the lift table.
7. Raise the engine and transaxle into the vehicle.
8. Install the rear transaxle mount. Tighten the nuts to 115 Nm (85 lb-ft). Tighten the bolt to 90 Nm (66 lb-ft).
9. Install the rear transaxle mount brace. Tighten to 25 Nm (18 lb-ft).
10. Install the RH transaxle mount bracket. Tighten to 90 Nm (66 lb-ft).
11. Install the RH transaxle mount bracket nut. Tighten to 90 Nm (66 lb-ft).
12. Install the engine mount bracket. Tighten to 90 Nm (66 lb-ft).
13. Install the engine mount bracket bolt. Tighten to 90 Nm (66 lb-ft).
14. Install the 2 transaxle-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
15. Install the 2 transaxle-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
16. Install the engine support crossmember. Tighten to the bolts to 90 Nm (66 lb-ft). Tighten to the nut to 175 Nm (129 lb-ft).
17. Install the rear roll restrictor bolt. Tighten to 90 Nm (66 lb-ft).
18. Install the front roll restrictor bolt. Tighten to 115 Nm (85 lb-ft).
19. Install the A/C compressor and connect the A/C compressor electrical connector. Tighten to 25 Nm (18 lb-ft).
20. Connect the lower radiator hose to the radiator.
21. Install the motor electronics coolant pump. Tighten to 7 Nm (62 lb-in).
22. Install the ground cable and nut. Tighten to 20 Nm (15 lb-ft).
23. Connect the transaxle coolant hoses.
24. Connect the transaxle coolant temperature sensor electrical connector and pin-type retainer.
25. Position the transaxle control cable and connect the pin-type retainer.
26. Connect the pin-type retainer.
27. Connect the transaxle control cable. Install the transaxle control cable bracket and the 2 nuts finger tight. Attach the transaxle control cable to the control lever.
28. Position the control lever between the 2 casting ribs on the transaxle case.
29. Place the gear selector lever in the D position.
30. Tighten the transaxle control cable bracket nuts to 22 Nm (16 lb-ft).
31. To verify the correct cable adjustment, observe the control lever on the transaxle while an assistant shifts the gear selector lever to each range position ending in the D position.
32. Install the transaxle control snow shield. Tighten to 22 Nm (16 lb-ft).
33. Install the auxiliary coolant pump and connect the electrical connector. Tighten to 10 Nm (89 lb-in).
34. If equipped, install the block heater wiring harness. Route the harness through the radiator support. Attach the 3 harness retainer clips.
35. Install the fuel supply tube and evaporative emissions (EVAP) tube.
36. Connect the DC-to-DC converter electrical connector and pin-type retainer.
37. Connect the transaxle harness electrical connector and install the bolt. Tighten to 10 Nm (89 lb-in).
38. Connect the 2 engine control harness electrical connectors and the 2 pin-type retainers.
39. Connect the engine control harness. Engage the powertrain control module (PCM) connector. Install the harness retaining nut. Tighten to 6 Nm (53 lb-in).
40. Connect the following electrical connectors: Transaxle mount control solenoid Purge valve
41. Connect the upper radiator and coolant vent hoses.
42. Attach the heater hose retaining clip to the transaxle mount stud.
43. Connect the heater hoses to the heater core.
44. Install the lateral support crossmember. Tighten to 115 Nm (85 lb-ft).
45. Install the front drive intermediate halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-232197) .
46. Install the transfer case. For additional information, refer to «TRANSFER CASE-POWER TRANSFER UNIT (PTU)»(ref-232190) .
47. Install the LH front drive halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-232197) .
48. Install the oil filter element. For additional information, refer to «ENGINE LUBRICATION COMPONENTS - EXPLODED VIEW»(ref-232196-S31602258832006051600000) .
49. Install the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - HYBRID»(ref-232226) .
50. Install the engine coolant degas bottle. For additional information, refer to «ENGINE COOLING - HYBRID»(ref-232208) .
51. Install the catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-232210) .
52. Install the engine air cleaner. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - HYBRID»(ref-232206) .
53. Install the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(ref-232196-S21740448342006051600000) .
54. Enable the vehicle high voltage electrical system. For additional information, refer to «HIGH VOLTAGE TRACTION BATTERY»(ref-232253) .
55. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-232248) .
56. Fill the engine with clean engine oil.
57. Fill and bleed the motor electronics cooling system. For additional information, refer to «TRANSAXLE-TRANSMISSION COOLING - HYBRID»(ref-232264) .
58. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING - HYBRID»(ref-232208) .