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Engine Front Cover: Removal

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, may cause engine failure.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING .
  2. Recover the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .
  3. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  4. Remove the accessory drive belt, tensioner and the power steering belt. For additional information, refer to ACCESSORY DRIVE .
  5. Using the special tool, remove the crankshaft bolt and washer.
    • Discard the bolt.
    6. Fig 1: Removing Crankshaft Bolt & Washer Using Special Tool (303-D055)
    GF0029103Courtesy of FORD MOTOR CO.
  6. Using the special tool, remove the crankshaft pulley.
    7. Fig 2: Removing Crankshaft Pulley Using Special Tool (303-D121)
    GF0017017Courtesy of FORD MOTOR CO.
  7. Using the special tool, remove and discard the crankshaft front seal.
    8. Fig 3: Removing Crankshaft Front Seal Using Special Tool (303-409)
    GF0029106Courtesy of FORD MOTOR CO.
  8. Loosen the exhaust flexible pipe clamp and disconnect the 2 exhaust hangers.
    9. Fig 4: Locating Exhaust Flexible Pipe Clamp & Exhaust Hangers
    GF0031305Courtesy of FORD MOTOR CO.
  9. Remove the 4 nuts, the exhaust flexible pipe and the Y-pipe as an assembly.
    • Discard the nuts and the gasket.
    10. Fig 5: Locating Exhaust Flexible Pipe, Y-Pipe & Nuts
    GF0031306Courtesy of FORD MOTOR CO.
  10. Remove the 2 nuts and the roll restrictor heat shield.
    11. Fig 6: Locating Roll Restrictor Heat Shield Nuts
    GF0031344Courtesy of FORD MOTOR CO.
  11. Remove the roll restrictor through bolt and the 2 roll restrictor-to-transaxle bracket plate bolts.
    12. Fig 7: Locating Roll Restrictor-To-Transaxle Bracket Plate Bolts
    GF0031345Courtesy of FORD MOTOR CO.
  12. Loosen the roll restrictor-to-subframe through bolt.
    • Position the roll restrictor and transaxle bracket plate aside.
    13. Fig 8: Locating Roll Restrictor-To-Subframe Bolt
    GF0031346Courtesy of FORD MOTOR CO.
  13. Remove the 3 bolts and the transaxle bracket.
    14. Fig 9: Locating Transaxle Bracket Bolts
    GF0031347Courtesy of FORD MOTOR CO.
  14. Remove and discard the RH front halfshaft nut.
    15. Fig 10: Locating RH Front Halfshaft Nut
    GF0031348Courtesy of FORD MOTOR CO.
  15. Remove the RH stabilizer link-to-lower control arm nut.
    16. Fig 11: Locating Stabilizer Bar Link Nut
    GF0031349Courtesy of FORD MOTOR CO.
  16. Remove the RH lower control arm-to-knuckle pinch bolt.
    • Separate the lower control arm from the knuckle.
    17. Fig 12: Locating Ball Joint Pinch Bolt
    GF0031304Courtesy of FORD MOTOR CO.
  17. Using the special tool, separate the RH halfshaft from the hub.
    18. Fig 13: Separating RH Halfshaft From Hub Using Special Tool (205-D070)
    GF0031350Courtesy of FORD MOTOR CO.
  18. Using the special tools, separate the RH halfshaft from the intermediate shaft.
    • Remove the RH halfshaft.
    19. Fig 14: Separating RH Halfshaft From Intermediate Shaft Using Special Tool (205-529) & (205-153)
    GF0031351Courtesy of FORD MOTOR CO.
  19. Remove the drain plug and drain the engine oil.
    • Install the drain plug and tighten to 27 Nm (20 lb-ft).
  20. If equipped, detach the engine block heater harness from the radiator support, the A/C suction tube and the engine wiring harness.
    21. Fig 15: Identifying Engine Block Heater Harness, Radiator Support, A/C Suction Tube & Engine Wiring Harness
    GF0031352Courtesy of FORD MOTOR CO.
  21. Remove the engine air cleaner and air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING .
  22. Remove the LH and RH valve covers. For additional information, refer to Valve Cover - LH  and Valve Cover - RH .
  23. Remove the safety clip from the A/C suction tube fitting.
    • Disconnect the A/C suction tube fitting and position the tube aside.
    24. Fig 16: Identifying Safety Clip On A/C Suction Tube Fitting
    GF0031353Courtesy of FORD MOTOR CO.
  24. Remove the A/C pressure tube bracket bolt.
    25. Fig 17: Locating A/C Pressure Tube Bracket Bolt
    GF0031354Courtesy of FORD MOTOR CO.
  25. Remove the nut and disconnect the A/C pressure tube fitting.
    • Discard the O-ring seal.
    • Position the A/C pressure tube aside.
    26. Fig 18: Locating A/C Pressure Tube Fitting Nut
    GF0031355Courtesy of FORD MOTOR CO.
  26. Disconnect the 2 engine wiring harness connectors.
    27. Fig 19: Locating Engine Wiring Harness Connectors
    GF0031356Courtesy of FORD MOTOR CO.
  27. Remove the bolt and the ground wire from the engine front cover.
    28. Fig 20: Removing Bolt & Ground Wire From Engine Front Cover
    GF0031357Courtesy of FORD MOTOR CO.
  28. Remove the nut, the ground wire and the radio interference capacitor wire from the engine front cover stud.
    29. Fig 21: Removing Nut, Ground Wire & Radio Interference Capacitor Wire From Engine Front Cover Stud
    GF0031358Courtesy of FORD MOTOR CO.
  29. Remove the nut, the ground wire and the radio interference capacitor from the cowl stud.
    30. Fig 22: Removing Nut, Ground Wire & Radio Interference Capacitor Wire From Cowl Stud
    GF0031359Courtesy of FORD MOTOR CO.
  30. Disconnect the purge valve electrical connector.
    31. Fig 23: Locating Purge Valve Electrical Connector
    GF0031360Courtesy of FORD MOTOR CO.
  31. Disconnect the 3 PCM electrical connectors and position the wiring harness aside.
    32. Fig 24: Identifying PCM Electrical Connectors
    GF0031361Courtesy of FORD MOTOR CO.
  32. Remove the 3 bolts and position the degas bottle aside.
    33. Fig 25: Identifying Bolts & Position Degas Bottle Aside
    GF0031362Courtesy of FORD MOTOR CO.
    NOTE: The area between the front of the engine and the body of the vehicle must be unobstructed in order to properly remove and install the engine front cover.
  33. Remove the 2 power steering reservoir nuts.
    • Support the power steering reservoir and hose away from the front of the engine with a length of mechanic's wire.
    34. Fig 26: Locating Power Steering Reservoir Nuts
    GF0031363Courtesy of FORD MOTOR CO.
  34. Remove the 3 power steering pump bolts.
    • Support the power steering pump and hose away from the front of the engine with a length of mechanic's wire.
    35. Fig 27: Locating Power Steering Pump Bolts
    GF0029184Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  35. Remove the bolts, the LH and the RH VCT solenoids.
    36. Fig 28: Locating LH & RH VCT Solenoids Bolts
    GF0031364Courtesy of FORD MOTOR CO.
    CAUTION: The special tool must be carefully aligned to the mounting bosses on the oil pan. Failure to follow these instructions may result in damage to the oil pan.
    NOTE: The special tool and floor jack are used to raise and lower the engine to access the engine front cover and engine mount bracket fasteners.
  36. Position a floor jack and the special tool under the oil pan.
    37. Fig 29: Positioning Floor Jack & Special Tool (303-1295) Under Oil Pan
    GF0029124Courtesy of FORD MOTOR CO.
    CAUTION: The transaxle through bolt must be loosened prior to removing the engine mount and lowering the front of the engine. Failure to follow these instructions may cause internal damage to the hydraulic transaxle mount and possible fluid leakage.
  37. Loosen the transaxle mount through bolt.
    38. Fig 30: Identifying Transaxle Mount Bolt
    GF0031365Courtesy of FORD MOTOR CO.
  38. Remove the nut, bolt and engine mount brace.
    39. Fig 31: Locating Nut, Bolt & Engine Mount Brace
    GF0031366Courtesy of FORD MOTOR CO.
  39. Remove the 4 engine mount nuts.
    40. Fig 32: Locating Engine Mount Nuts
    GF0031367Courtesy of FORD MOTOR CO.
  40. Remove the 3 bolts and the engine mount.
    41. Fig 33: Locating Engine Mount Bolts
    GF0031368Courtesy of FORD MOTOR CO.
  41. Remove the 2 bolts and the engine mount bracket.
    42. Fig 34: Locating Engine Mount Bracket & Bolts
    GF0029186Courtesy of FORD MOTOR CO.
  42. Remove the 2 engine mount studs.
    43. Fig 35: Locating Engine Mount Studs
    GF0029187Courtesy of FORD MOTOR CO.
  43. Remove the 2 upper engine mount bracket bolts.
    44. Fig 36: Locating Upper Engine Mount Bracket Bolts
    GF0031369Courtesy of FORD MOTOR CO.
  44. Lower the engine to access the lower engine mount bracket bolt.
  45. Loosen the lower engine mount bracket bolt and remove the engine mount bracket and bolt as an assembly.
    46. Fig 37: Locating Lower Engine Mount Bracket Bolt
    GF0031370Courtesy of FORD MOTOR CO.
  46. Remove the 22 engine front cover bolts.
    47. Fig 38: Identifying Engine Front Cover Bolts
    GF0029189Courtesy of FORD MOTOR CO.
  47. Install 6 of the engine front cover bolts (finger tight) into the 6 threaded holes in the engine front cover.
    • Tighten the bolts one turn at a time in a criss-cross pattern until the engine front cover-to-cylinder block seal is released.
      • Remove the engine front cover.
    48. Fig 39: Identifying Engine Front Cover Bolts
    GF0029190Courtesy of FORD MOTOR CO.
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