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Engine Front Cover: Removal

CAUTION: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. 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 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 bolt. 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.
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. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING .
  2. Remove the accessory drive belt and idler pulleys. For additional information, refer to ACCESSORY DRIVE .
  3. Remove the crankshaft pulley. For additional information, refer to CRANKSHAFT PULLEY  in this article.
  4. Remove the engine mount. For additional information, refer to ENGINE MOUNT  in this article.
  5. If equipped, detach the 2 wiring harness retainers from the power steering reservoir.
  6. Disconnect the power steering pressure (PSP) switch electrical connector.
  7. Using the special tool, remove the power steering pump pulley.
    Fig 1: Identifying Special Tool (211-016)
    G04651975Courtesy of FORD MOTOR CO.
  8. Remove the PSP tube bracket nut.
    9. NOTE: A new Teflon® O-ring seal must be installed any time the PSP tube is disconnected from the power steering pump.
  9. Disconnect the PSP tube from the power steering pump.
    • Remove and discard the Teflon® O-ring seal.
  10. Remove the 4 power steering pump mounting bolts and position the power steering pump aside.
    11. CAUTION: Use care not to damage the engine front cover or the crankshaft when removing the seal.
    Fig 2: Locating Crankshaft Front Oil Seal And Special Tool
    G04651976Courtesy of FORD MOTOR CO.
  11. Using the special tool, remove the crankshaft front oil seal.
  12. Remove the 3 bolts and the coolant pump pulley.
  13. Disconnect the crankshaft position (CKP) sensor electrical connector.
    • Detach the 2 wiring harness retainers from the engine front cover.
    14. NOTE: Whenever the CKP sensor is removed, a new part must be installed, using the alignment jig supplied with the new part.
  14. Remove and discard the CKP sensor.
  15. Remove the bolts and the engine front cover.
    Fig 3: Locating Engine Front Cover Bolts
    G03897743Courtesy of FORD MOTOR CO.
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