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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 article.
  2. Recover the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS article.
  3. Remove the air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING article.
  4. Remove the front wheels and tires. For additional information, refer to WHEELS AND TIRES article.
  5. Remove the accessory drive belt, tensioner and the power steering belt. For additional information, refer to ACCESSORY DRIVE article.
  6. Remove the degas bottle. For additional information, refer to ENGINE COOLING article.
  7. Remove the 2 nuts and disconnect the A/C tubes.
    • Discard the O-ring seals.
    8. Fig 1: Identifying Nuts
    GF0045626Courtesy of FORD MOTOR CO.
  8. Remove the nut and the A/C tube-to-receiver/drier.
    • Discard the O-ring seal.
    9. Fig 2: Identifying Nut
    GF0045627Courtesy of FORD MOTOR CO.
  9. Disconnect the power steering cooler tube and drain the power steering fluid into a suitable container.
    10. Fig 3: Identifying Power Steering Cooler Tube
    GF0045628Courtesy of FORD MOTOR CO.
  10. Remove the RH inner fender splash shield. For additional information, refer to FRONT END BODY PANELS article.
  11. Using the special tool, remove the crankshaft bolt and washer.
    • Discard the bolt.
    12. Fig 4: Removing Crankshaft Bolt & Washer Using Special Tool (303-D055)
    GF0029103Courtesy of FORD MOTOR CO.
  12. Using the special tool, remove the crankshaft pulley.
    13. Fig 5: Identifying Special Tools (303-D121) And Crankshaft Pulley
    GF0017017Courtesy of FORD MOTOR CO.
  13. Using the special tool, remove and discard the crankshaft front seal.
    14. Fig 6: Removing Crankshaft Front Seal Using Special Tool (303-409)
    GF0029106Courtesy of FORD MOTOR CO.
  14. Remove the 4 nuts and the Y-pipe-to-catalytic converter nuts.
    • Discard the nuts.
    15. Fig 7: Identifying Nuts
    GF0045629Courtesy of FORD MOTOR CO.
  15. Remove the 2 Y-pipe flange nuts.
    • Detach the exhaust hanger and remove the Y-pipe.
    • Discard the gaskets and nuts.
    16. Fig 8: Identifying Nuts And Exhaust Hanger
    GF0045630Courtesy of FORD MOTOR CO.
  16. Remove the drain plug and drain the engine oil.
    • Install the drain plug and tighten to 27 Nm (20 lb-ft).
    17. Fig 9: Locating Drain Plug
    GF0029140Courtesy of FORD MOTOR CO.
  17. Disconnect the hose from the power steering reservoir.
    18. Fig 10: Disconnecting Hose From Power Steering Reservoir
    GF0031386Courtesy of FORD MOTOR CO.
  18. Remove the RH and LH valve covers. For additional information, refer to Valve Cover - LH  and Valve Cover - RH .
  19. Remove the bolt and the ground cable.
    20. Fig 11: Identifying Bolt And Ground Cable
    GF0045631Courtesy of FORD MOTOR CO.
  20. Disconnect the fuel efficient power steering system solenoid electrical connector.
    21. Fig 12: Identifying Connector
    GF0045632Courtesy of FORD MOTOR CO.
  21. Disconnect the power steering pressure (PSP) switch electrical connector.
    22. Fig 13: Identifying PSP Connector
    GF0045633Courtesy of FORD MOTOR CO.
  22. Remove the PSP tube bracket-to-power steering pump bolt.
    23. Fig 14: Identifying Bracket-To-Power Steering Pump Bolt
    GF0045634Courtesy of FORD MOTOR CO.
  23. Remove the 3 bolts and position aside the power steering pump.
    24. Fig 15: Identifying Bolts
    GF0045635Courtesy 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.
  24. Position a floor jack and the special tool under the oil pan.
    25. Fig 16: Positioning Floor Jack & Special Tool (303-1295) Under Oil Pan
    GF0029124Courtesy of FORD MOTOR CO.
  25. Remove the nut, bolt and engine mount brace.
    26. Fig 17: Identifying Nut, Bolt And Brace
    GF0045636Courtesy of FORD MOTOR CO.
  26. Remove the 4 engine mount nuts.
    27. Fig 18: Identifying Mounting Nuts
    GF0045637Courtesy of FORD MOTOR CO.
  27. Remove the 3 bolts and the engine mount.
    28. Fig 19: Identifying Engine Mount And Bolts
    GF0045638Courtesy of FORD MOTOR CO.
  28. Remove the 2 bolts and the engine mount bracket.
    29. Fig 20: Locating Engine Mount Bracket & Bolts
    GF0029186Courtesy of FORD MOTOR CO.
  29. Remove the 2 engine mount studs.
    30. Fig 21: Locating Engine Mount Studs
    GF0029187Courtesy of FORD MOTOR CO.
  30. Remove the 2 upper engine mount bracket bolts.
    31. Fig 22: Locating Upper Engine Mount Bracket Bolts
    GF0031369Courtesy of FORD MOTOR CO.
  31. Loosen the lower engine mount bracket bolt and remove the engine mount bracket and bolt as an assembly.
    32. Fig 23: Locating Lower Engine Mount Bracket Bolt
    GF0031370Courtesy of FORD MOTOR CO.
  32. Remove the A/C tube bracket bolt.
    33. Fig 24: Identifying A/C Tube Bracket Bolt
    GF0045639Courtesy of FORD MOTOR CO.
  33. Remove the A/C tube retaining clamp bolt.
    34. Fig 25: Identifying Retaining Clamp Bolt
    GF0045640Courtesy of FORD MOTOR CO.
  34. Remove the A/C tube-to-evaporator bolt and the 2 A/C tubes.
    • Discard the O-ring seals.
    35. Fig 26: Identifying Bolt And A/C Tubes
    GF0045641Courtesy of FORD MOTOR CO.
  35. Using the floor jack, raise the engine slightly.
  36. Remove the 22 engine front cover bolts.
    37. Fig 27: Identifying Engine Front Cover Bolts
    GF0029189Courtesy of FORD MOTOR CO.
  37. 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.
    38. Fig 28: Identifying Engine Front Cover Bolts
    GF0029190Courtesy of FORD MOTOR CO.
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