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Home >> Ford >> 2000 >> ZX2 Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1327 (Engine - 2.3L) >> In-Vehicle Repair >> Engine Front Cover >> Removal
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Engine Front Cover: Removal

WARNING: This page is about a different car, the 2004 Ford Focus. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: 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.
  1. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
    2. CAUTION: 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 you loosen the pulley. Therefore the engine must be retimed each time the damper is removed. Otherwise severe engine damage can occur.
  2. Remove the crankshaft pulley. For additional information, refer to CRANKSHAFT PULLEY .
  3. Release the wiring harness.
    1. Remove the nuts retaining the wiring harness.
    2. Release the wiring harness from the front cover studs and position aside.
    Fig 1: Releasing Wiring Harness
    G04035465Courtesy of FORD MOTOR CO.
    4. NOTE: If the crankshaft position (CKP) sensor is damaged during engine front cover removal a new CKP sensor must be installed. Refer to the manufacturer instructions for sensor installation.
    Fig 2: Disconnecting CKP Sensor Electrical Connector
    G04035466Courtesy of FORD MOTOR CO.
  4. Disconnect the CKP sensor electrical connector.
  5. Remove the accessory belt tensioner.
    1. Remove the bolts.
    2. Remove the tensioner.
    Fig 3: Removing Accessory Belt Tensioner
    G04035467Courtesy of FORD MOTOR CO.
  6. Disconnect the power steering pressure (PSP) switch electrical connector.
    Fig 4: Disconnecting Power Steering Pressure Switch Electrical Connector
    G04035468Courtesy of FORD MOTOR CO.
  7. Remove the nut and detach the PSP tube bracket.
    Fig 5: Removing PSP Tube Bracket Nut
    G04035469Courtesy of FORD MOTOR CO.
  8. Using the special tool, remove the power steering pump pulley.
    Fig 6: Removing Power Steering Pump Pulley
    G04035470Courtesy of FORD MOTOR CO.
  9. Disconnect the PSP tube.
    • Remove and discard the O-ring seal.
    Fig 7: Disconnecting PSP Tube
    G04035471Courtesy of FORD MOTOR CO.
  10. Remove the four bolts and position the power steering pump aside.
    Fig 8: Removing Power Steering Pump Bolts
    G04035472Courtesy of FORD MOTOR CO.
  11. Remove the coolant pump pulley.
    Fig 9: Removing Coolant Pump Pulley
    G04035473Courtesy of FORD MOTOR CO.
  12. Remove the RH motor mount. For additional information, refer to ENGINE MOUNT - RH .
  13. Remove the accessory drive belt idler pulley.
    Fig 10: Removing Accessory Drive Belt Idler Pulley
    G04035474Courtesy of FORD MOTOR CO.
  14. Remove the retainers and the engine front cover.
    Fig 11: Removing Retainers And Engine Front Cover
    G04035475Courtesy of FORD MOTOR CO.
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