Ford Fusion Manuals

Ford Fusion: Engine - 1.5L EcoBoost (118kW/160PS) – I4 / Engine. Disassembly

Special Tool(s) / General Equipment

Ford Fusion. Engine. Disassembly 100-001 (T50T-100-A)
Slide Hammer
Ford Fusion. Engine. Disassembly 300-OTC1819E
2,200# Floor Crane, Fold Away
Ford Fusion. Engine. Disassembly 303-1097
Locking Tool, Variable Camshaft Timing Oil Control Unit
TKIT-2010B-FLM
TKIT-2010B-ROW
Ford Fusion. Engine. Disassembly 303-1502
Lifting Device Engine
TKIT-2012A-FL
TKIT-2012A-ROW
Ford Fusion. Engine. Disassembly 303-409 (T92C-6700-CH)
Remover, Crankshaft Seal
TKIT-1992-FH/FMH/FLMH
TKIT-1993-LMH/MH
Ford Fusion. Engine. Disassembly 303-748
Locking Tool, Crankshaft
TKIT-2010B-FLM
TKIT-2010B-ROW
Ford Fusion. Engine. Disassembly 307-005 (T59L-100-B)
Slide Hammer
Ford Fusion. Engine. Disassembly 308-375
Remover, Input Shaft Seal
TKIT-2005U-M
TKIT-1999-F/FLM/LT
Ford Fusion. Engine. Disassembly 310-206
Remover, Fuel Injector
TKIT-2009A-FLM
Hot Air Gun
Hose Clamp Remover/Installer

Materials

Name Specification
Motorcraft® Metal Brake Parts Cleaner
PM-4-A, PM-4-B
-
 

NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. 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.

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 the oil pan, can cause engine failure.

NOTE: Refer to exploded views in Description and Operation.

  1. Remove the bolts and the flexplate. Discard the bolts.
Ford Fusion. Engine. Disassembly
  1. Mount the engine to the engine stand.
Ford Fusion. Engine. Disassembly
  1. Remove Special Service Tool: 300-OTC1819E  2,200# Floor Crane, Fold Away.
Ford Fusion. Engine. Disassembly
  1. Remove Special Service Tool: 303-1502  Lifting Device Engine.
Ford Fusion. Engine. Disassembly
  1. Remove the coolant hose.
    Use the General Equipment: Hose Clamp Remover/Installer
Ford Fusion. Engine. Disassembly
  1. Remove the coolant hose.
    Use the General Equipment: Hose Clamp Remover/Installer
Ford Fusion. Engine. Disassembly
  1. Detach the wiring harness retainer and disconnect the electrical connector.
Ford Fusion. Engine. Disassembly
  1. Disconnect all the coolant hoses.
    Use the General Equipment: Hose Clamp Remover/Installer
Ford Fusion. Engine. Disassembly
  1. Remove the coolant hoses.
    Use the General Equipment: Hose Clamp Remover/Installer
Ford Fusion. Engine. Disassembly
  1. Disconnect the PCV hose couplings and remove the hoses.
    Use the General Equipment: Hose Clamp Remover/Installer
Ford Fusion. Engine. Disassembly
  1. Remove the bolts and the A/C compressor.
Ford Fusion. Engine. Disassembly
  1. Remove the bolts and the bracket.
Ford Fusion. Engine. Disassembly
    • Remove the nut, stud, stud bolt and the generator.
    • Remove the bolt and the accessory drive belt idler pulley.
Ford Fusion. Engine. Disassembly
    • Detach the retainers and disconnect the CKP sensor electrical connector.
    • Remove the stud bolt and position the wiring harness aside.
Ford Fusion. Engine. Disassembly
    • Detach the wiring harness retainer and remove the retainer.
    • Disconnect the electrical connectors and position the wiring harness aside.
Ford Fusion. Engine. Disassembly
  1. Detach the wiring harness retainers and disconnect the electrical connectors.
Ford Fusion. Engine. Disassembly
  1. Detach the wiring harness retainers and disconnect the electrical connectors.
Ford Fusion. Engine. Disassembly
  1. Detach the wiring harness retainers and disconnect the electrical connectors.
Ford Fusion. Engine. Disassembly
  1. Position the cover and disconnect the CHT sensor wiring harness electrical connector.
Ford Fusion. Engine. Disassembly
    • Detach the retainers, disconnect the electrical connectors and remove the wiring harness.
    • Remove the oil level indicator.
Ford Fusion. Engine. Disassembly
  1. Disconnect the vacuum hose and retainer.
Ford Fusion. Engine. Disassembly
    • Remove the nut and the coolant outlet. Discard the nut.
    • Detach the retainers and position the vacuum hose aside.
    • Remove the nuts, bolt and the brackets.
Ford Fusion. Engine. Disassembly
  1. Inspect the coolant outlet O-ring seal.
Ford Fusion. Engine. Disassembly
    • Remove the stud bolts and the vacuum pump. Discard the stud bolts.
    • Remove the bolts and the engine lifting bracket.
    • Remove the bolt and stud.
Ford Fusion. Engine. Disassembly
  1. Remove and discard the vacuum pump gasket.
Ford Fusion. Engine. Disassembly
    • Detach the retainers and remove the TC wastegate control hose.
    • Remove the nut, bolt and the bracket.
Ford Fusion. Engine. Disassembly
  1. Remove the retainers and position the TC coolant tube aside.
Ford Fusion. Engine. Disassembly
  1. Remove the retainers and the TC coolant tube.
Ford Fusion. Engine. Disassembly
    • NOTICE: Do-not use a metal brush; damage to sealing area will result in leaks.

      Inspect the turbocharger tube and the sealing surfaces. Ensure that the retaining bracket is not bent, check for square-ness of the retaining bracket to the O-ring area. Use brake cleaner and a nylon brush to clean.
    1. Remove and discard the TC coolant tube O-ring seals.
      Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B
Ford Fusion. Engine. Disassembly
  1. Remove the bolts, stud bolt and the CAC.
Ford Fusion. Engine. Disassembly
  1. NOTE: Bolts remain captured in the intake manifold.

    Remove the bolts and the intake manifold.
Ford Fusion. Engine. Disassembly
  1. NOTE: Note the position of the component before removal.

    Remove the bolts and the VCT oil control solenoids.
Ford Fusion. Engine. Disassembly
  1. NOTE: The O-ring seals are to be reused unless damaged.

    Inspect the VCT oil control solenoid O-ring seal.
Ford Fusion. Engine. Disassembly
    • Remove the bolts and the ignition coil-on-plugs.
    • Remove the bolts and the CMP sensors.
Ford Fusion. Engine. Disassembly
  1. NOTE: Replace any damaged coil-on-plug assemblies.

    Inspect the coil-on-plug.
Ford Fusion. Engine. Disassembly
  1. Loosen the flare nuts and remove and discard the high-pressure fuel tube.
Ford Fusion. Engine. Disassembly
  1. Remove the retainers and the high-pressure fuel pump. Discard the retainers.
Ford Fusion. Engine. Disassembly
  1. Remove and discard the high-pressure fuel pump O-ring seal.
Ford Fusion. Engine. Disassembly
  1. Remove the high-pressure fuel pump tappet.
Ford Fusion. Engine. Disassembly
  1. Inspect the high-pressure fuel pump tappet.
Ford Fusion. Engine. Disassembly
  1. Disconnect the electrical connectors and remove the wiring harness.
Ford Fusion. Engine. Disassembly
  1. NOTICE: 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 the bolts and the fuel rail assembly.
Ford Fusion. Engine. Disassembly
  1. NOTE: Take extra care when handling the components.

    NOTE: Remove any of the fuel injectors that remained in the fuel rail.

    Remove clip and any of the fuel injectors that remained in the fuel rail.
Ford Fusion. Engine. Disassembly
  1. Remove and discard the fuel injector clip.
Ford Fusion. Engine. Disassembly
  1. NOTE: Remove the fuel injectors that remained in the head.

    Using the special tools, remove the fuel injector.
    Use Special Service Tool: 307-005 (T59L-100-B)  Slide Hammer. , 310-206  Remover, Fuel Injector.
Ford Fusion. Engine. Disassembly
  1. NOTICE: Do not set the valve cover sealing surface face down on a bench as the check valve and splitter leg is susceptible to breakage.

    Remove the bolts as shown in sequence and remove the valve cover.
Ford Fusion. Engine. Disassembly
  1. Remove and discard valve cover gasket.
Ford Fusion. Engine. Disassembly
  1. NOTICE: Use a heat gun to soften the flange sealant, this will aid in the removal of the fuel pump mounting bracket. Failure to follow these directions may result in damage to the fuel pump mounting bracket.

    • Remove the bolts in sequence shown, heat and break the adhesive bond and remove the high-pressure fuel pump drive unit.
      Use the General Equipment: Hot Air Gun
    • Remove and discard the O-ring seal.
Ford Fusion. Engine. Disassembly
  1. NOTICE: Use a heat gun to soften the flange sealant, this will aid in the removal of the fuel pump mounting bracket. Failure to follow these directions may result in damage to the fuel pump mounting bracket.

    • Remove the engine cover mounting stud.
    • Remove the bolts and the stud.
    • Heat and break the adhesive bond and remove the brake vacuum pump cap.
      Use the General Equipment: Hot Air Gun
Ford Fusion. Engine. Disassembly
  1. Remove the retainer and the oil cooler. Discard the retainer.
Ford Fusion. Engine. Disassembly
  1. NOTE: Note the position for installation.

    Detach the retainer, remove the bolts and the KS.
Ford Fusion. Engine. Disassembly
    • Remove the bolt, disconnect the coupling and remove the crankcase vent oil separator inlet pipe.
    • Remove the bolts and the crankcase vent oil separator.
Ford Fusion. Engine. Disassembly
  1. Remove and discard the oil pressure switch.
Ford Fusion. Engine. Disassembly
  1. Remove the nut, stud and the thermostat housing.
Ford Fusion. Engine. Disassembly
  1. Inspect the thermostat housing O-ring seal.
Ford Fusion. Engine. Disassembly
  1. Remove the bolts and the TC heat shield.
Ford Fusion. Engine. Disassembly
    1. Remove the TC oil return tube to TC bolts.
    1. Remove the TC oil return tube to engine block bolt and remove and discard the TC oil return tube.
Ford Fusion. Engine. Disassembly
  1. Remove and discard the TC oil return tube gasket. Clean the sealing surface.
Ford Fusion. Engine. Disassembly
  1. Remove the nuts, retainer and the TC. Discard the nuts.
Ford Fusion. Engine. Disassembly
  1. Remove the and discard the TC oil supply tube assembly, including the bolt, the sealing washers and the O-rings seals.
Ford Fusion. Engine. Disassembly
  1. Remove and discard the TC mounting gasket and studs.
Ford Fusion. Engine. Disassembly
  1. NOTE: Note the position for installation.

    If equipped with block heater, remove the nut and the block heater.
Ford Fusion. Engine. Disassembly
  1. Remove the stud bolt and position the cover from engine front cover aside.
Ford Fusion. Engine. Disassembly
    • Remove the bolts and the coolant pump pulley.
    • Remove the engine mount stud.
    • Remove the engine front cover bolts.
Ford Fusion. Engine. Disassembly
  1. Remove the engine front cover.
Ford Fusion. Engine. Disassembly
  1. NOTE: Note the different lengths of the bolts.

    Remove the bolts and the engine mount bracket.
Ford Fusion. Engine. Disassembly
  1. NOTE: Only rotate the crankshaft in a clockwise direction.

    Rotate the crankshaft pulley until the timing marks at the 11 o'clock position.
Ford Fusion. Engine. Disassembly
  1. Remove the engine plug bolt.
Ford Fusion. Engine. Disassembly
  1. NOTE: The Crankshaft TDC Timing Pin 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 Special Service Tool: 303-748  Locking Tool, Crankshaft.
Ford Fusion. Engine. Disassembly
  1. NOTE: Only rotate the crankshaft clockwise direction.

    Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the TDC Timing Peg. The engine is now at TDC.
Ford Fusion. Engine. Disassembly
  1. Remove the bolt and the crankshaft pulley. Discard the bolt.
Ford Fusion. Engine. Disassembly
  1. Remove the retainer and the CKP sensor.
Ford Fusion. Engine. Disassembly
  1. NOTE: The timing mark of each VCT unit must be at the 12 o'clock position.

    Install Special Service Tool: 303-1097  Locking Tool, Variable Camshaft Timing Oil Control Unit.
Ford Fusion. Engine. Disassembly
  1. Ford Fusion. Engine. Disassembly  WARNING: The timing belt tensioner spring is under load. Extra care must be taken at all times when handling the tensioner. Failure to follow this instruction may result in personal injury.

    1. Rotate the timing belt tensioner clockwise.
    1. Install a holding pin.
Ford Fusion. Engine. Disassembly
  1. Remove the timing belt.
Ford Fusion. Engine. Disassembly
  1. Remove the crankshaft sprocket.
Ford Fusion. Engine. Disassembly
  1. Using the special tools, remove and discard the crankshaft front seal.
    Use Special Service Tool: 308-375  Remover, Input Shaft Seal. , 100-001 (T50T-100-A)  Slide Hammer.
Ford Fusion. Engine. Disassembly
  1. Ford Fusion. Engine. Disassembly  WARNING: The timing belt tensioner spring is under load. Extra care must be taken at all times when handling the tensioner. Failure to follow this instruction may result in personal injury.

    Remove the retainer and the timing belt tensioner
Ford Fusion. Engine. Disassembly
  1. Remove the bolts and the coolant pump. Discard the bolts.
Ford Fusion. Engine. Disassembly
  1. Remove and discard the coolant pump gasket.
Ford Fusion. Engine. Disassembly
  1. Remove Special Service Tool: 303-1097  Locking Tool, Variable Camshaft Timing Oil Control Unit.
Ford Fusion. Engine. Disassembly
  1. NOTE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.

    Remove the VCT unit caps.
Ford Fusion. Engine. Disassembly
  1. NOTE: Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.

    Remove the bolts and the VCT units. Discard the bolts.
Ford Fusion. Engine. Disassembly
  1. Using special tool, remove and discard the camshaft seals.
    Use Special Service Tool: 303-409 (T92C-6700-CH)  Remover, Crankshaft Seal.
Ford Fusion. Engine. Disassembly
  1. NOTICE: Use a heat gun to soften the flange sealant, this will aid in the removal of the camshaft mega cap. Failure to follow these directions may result in damage to the camshaft mega cap.

    NOTICE: Do not pry on camshafts when removing or damage to the camshafts may occur.

    NOTE: Note the location and orientation of each camshaft bearing cap and the position of the camshaft lobes on the No. 1 cylinder for installation reference.

    NOTE: Retain the original camshaft bearing cap bolts for reuse when measuring the valve clearance, if needed, during assembly.

    • Remove the bolts and the camshaft caps.
    • Heat and remove the mega cap.
      Use the General Equipment: Hot Air Gun
    • Remove the camshafts.
    • Discard the camshaft caps bolts.
Ford Fusion. Engine. Disassembly
  1. Remove the crankcase vent oil drain tube.
Ford Fusion. Engine. Disassembly
  1. Inspect crankcase vent oil drain tube and replace if damaged.
Ford Fusion. Engine. Disassembly
  1. Remove and discard the O-ring seal.
Ford Fusion. Engine. Disassembly
  1. 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.

    Remove the valve tappets.
Ford Fusion. Engine. Disassembly
  1. Inspect and install new components as necessary.
Ford Fusion. Engine. Disassembly
  1. NOTE: Make sure that the cylinder head is at ambient air temperature before removing the cylinder head bolts.

    Remove the bolts in the sequence shown and the cylinder head. Discard the bolts.
Ford Fusion. Engine. Disassembly
  1. Remove and discard the cylinder head gasket.
Ford Fusion. Engine. Disassembly
  1. Remove and discard the dowels.
Ford Fusion. Engine. Disassembly
  1. Check the cylinder block and cylinder head distortion.
    Refer to: Cylinder Head Distortion (303-00 Engine System - General Information, General Procedures).
    Refer to: Cylinder Block Distortion (303-00 Engine System - General Information, General Procedures).
  1. Remove Special Service Tool: 303-748  Locking Tool, Crankshaft.
Ford Fusion. Engine. Disassembly
  1. Remove the oil pan bolts.
Ford Fusion. Engine. Disassembly
  1. Using the pry pads, remove the oil pan.
Ford Fusion. Engine. Disassembly
  1. Remove the bolts and the crankshaft rear seal.
Ford Fusion. Engine. Disassembly
  1. Remove the bolts and the oil pump screen and pickup tube.
Ford Fusion. Engine. Disassembly
  1. NOTE: The O-ring seal is to be reused unless damaged.

    Inspect the oil pump screen and pickup tube O-ring seal.
Ford Fusion. Engine. Disassembly
  1. Remove the bolts and the oil pan baffle.
Ford Fusion. Engine. Disassembly
  1. NOTE: Note the position of the 3 different lengths of the bolts for installation.

    1. Remove the two M6 x 55 mm bolts.
    1. Remove the three M6 x 35 mm bolts.
    1. Remove the three M6 x 25 mm bolts and remove the oil pump.
Ford Fusion. Engine. Disassembly
  1. Remove and discard the oil pump gasket.
Ford Fusion. Engine. Disassembly
    1. Clean the bolt holes for the oil pump with Motorcraft® Metal Brake Parts Cleaner to remove all residual oil.
      Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B
    1. Use compressed air to remove any brake clean or oil in the oil pump bolt holes.
Ford Fusion. Engine. Disassembly
    1. Before removing the pistons, inspect the top of the cylinder bores.
    1. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad.
Ford Fusion. Engine. Disassembly
  1. NOTE: The connecting rod cap bolts are a torque-to-yield design. The original connecting rod cap bolts will be used when measuring the connecting rod large end bore during assembly. The connecting rod cap bolts will be discarded after measurement.

    NOTE: Clearly mark the connecting rods, connecting rod caps and connecting rod bearings in numerical order for correct orientation for reassembly.

    Remove the bolts and the connecting rod caps.
Ford Fusion. Engine. Disassembly
  1. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

    Using a connecting rod installer, repeat until all the piston/rod assemblies are removed from the engine block.
Ford Fusion. Engine. Disassembly
  1. NOTE: Mark the position of the parts, so they can be installed in their original positions.

    Remove the connecting rod main bearings.
Ford Fusion. Engine. Disassembly
  1. Inspect the pistons.
    Refer to: Piston Inspection (303-00 Engine System - General Information, General Procedures).
  1. NOTE: The main bearing beam has 2 arrows pointing towards the front of engine for correct orientation for reassembly.

    Remove the bolts in sequence shown and the main bearing beam.
Ford Fusion. Engine. Disassembly
  1. NOTE: If the main bearings are being reused, mark them in order for correct orientation and reassembly.

    Remove the crankshaft main beam bearings.
Ford Fusion. Engine. Disassembly
  1. Remove the crankshaft.
Ford Fusion. Engine. Disassembly
  1. 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.

    Remove the crankshaft main bearings.
Ford Fusion. Engine. Disassembly
  1. Remove the bolts and the engine piston oil cooler valves.
Ford Fusion. Engine. Disassembly

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