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Engine Front Cover: Removal

WARNING: This page is about a different car, the 2009 Ford Flex. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: 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.

All vehicles 

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Recover the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .
  3. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
  4. Remove the front wheels and tires. For additional information, refer to WHEELS & TIRES .
  5. Remove the accessory drive belt, tensioner and the power steering belt. For additional information, refer to ACCESSORY DRIVE .
  6. Remove the degas bottle. For additional information, refer to ENGINE COOLING .
  7. Remove the Evaporative Emission (EVAP) canister purge valve. For additional information, refer to EVAPORATIVE EMISSIONS .
  8. Remove the 2 nuts and disconnect the A/C tubes.
    • Discard the O-ring seals.
      Fig 1: Locating Nuts And A/C Tubes
      G06061962Courtesy of FORD MOTOR CO.
  9. Remove the bolt and the A/C tube-to-receiver/drier.
    • Discard the O-ring seal.
      Fig 2: Locating Bolt And A/C Tube-To-Receiver/Drier
      G06061963Courtesy of FORD MOTOR CO.

    10. Vehicles with rear A/C 

  10. Remove the nut and disconnect the rear A/C tube.
    • Discard the O-ring seal.
      Fig 3: Locating Nut And Rear A/C Tube
      G06061964Courtesy of FORD MOTOR CO.
  11. Working from under the vehicle, remove the nut and disconnect the rear A/C tube.
    • Discard the O-ring seal.
      Fig 4: Locating Nut And Rear A/C Tube
      G06061965Courtesy of FORD MOTOR CO.

    12. All vehicles 

  12. Disconnect the power steering cooler tube and drain the power steering fluid into a suitable container.
    Fig 5: Locating Power Steering Cooler Tube
    G06061966Courtesy of FORD MOTOR CO.
  13. Remove the RH inner fender splash shield. For additional information, refer to FRONT END BODY PANELS .
  14. Using the Strap Wrench, remove the crankshaft bolt and washer.
    • Discard the bolt.
      Fig 6: Locating Crankshaft Bolt And Washer
      G06061937Courtesy of FORD MOTOR CO.
  15. Using the 3-Jaw Puller, remove the crankshaft pulley.
    Fig 7: Removing Crankshaft Pulley
    G06061968Courtesy of FORD MOTOR CO.
  16. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
    Fig 8: Removing Crankshaft Front Seal
    G06061944Courtesy of FORD MOTOR CO.
  17. Remove the 4 Y-pipe-to-catalytic converter nuts.
    • Discard the nuts.
      Fig 9: Locating Y-Pipe-To-Catalytic Converter Nuts
      G06061970Courtesy of FORD MOTOR CO.
  18. Remove the 2 Y-pipe flange nuts.
    • Detach the exhaust hanger and remove the Y-pipe.
    • Discard the gaskets and nuts.
      Fig 10: Locating Y-Pipe Flange Nuts
      G06061971Courtesy 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).
      Fig 11: Locating Drain Plug
      G06061972Courtesy of FORD MOTOR CO.
  20. Disconnect the hose from the power steering reservoir.
    Fig 12: Locating Power Steering Reservoir Hose
    G06061973Courtesy of FORD MOTOR CO.
  21. Remove the RH and LH valve covers. For additional information, refer to VALVE COVER - LH  and VALVE COVER - RH .
  22. Detach the wiring harness retainer from the engine mount bracket stud bolt.
    Fig 13: Locating Engine Mount Bracket Stud Bolt
    G06061974Courtesy of FORD MOTOR CO.
  23. Remove the bolt and the ground cable.
    Fig 14: Locating Bolt And Ground Cable
    G06061975Courtesy of FORD MOTOR CO.
  24. Disconnect the Power Steering Pressure (PSP) switch electrical connector.
    Fig 15: Locating Power Steering Pressure (PSP) Switch Electrical Connector
    G06061976Courtesy of FORD MOTOR CO.
  25. Remove the PSP  tube bracket-to-power steering pump bolt.
    Fig 16: Locating PSP Tube Bracket-To-Power Steering Pump Bolt
    G06061977Courtesy of FORD MOTOR CO.
  26. Remove the 3 bolts and position aside the power steering pump.
    Fig 17: Locating Bolts And Power Steering Pump
    G06061978Courtesy of FORD MOTOR CO.
    27. NOTE: The Oil Pan Holding Fixture 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.
    Fig 18: Positioning Floor Jack And Oil Pan Holding Fixture Under Oil Pan
    G06061979Courtesy of FORD MOTOR CO.
  27. Position a floor jack and the Oil Pan Holding Fixture under the oil pan.
  28. Remove the nut, bolt and engine mount brace.
    Fig 19: Locating Nut, Bolt And Engine Mount Brace
    G06061980Courtesy of FORD MOTOR CO.
  29. Remove the 4 engine mount nuts.
    Fig 20: Locating Engine Mount Nuts
    G06061981Courtesy of FORD MOTOR CO.
  30. Remove the 3 bolts and the engine mount.
    Fig 21: Locating Bolts And Engine Mount
    G06061982Courtesy of FORD MOTOR CO.
  31. Remove the 2 bolts and the engine mount bracket.
    Fig 22: Locating Bolts And Engine Mount Bracket
    G06061983Courtesy of FORD MOTOR CO.
    32. NOTE: Only use hand tools to remove the studs.
    Fig 23: Locating Engine Mount Studs
    G06061984Courtesy of FORD MOTOR CO.
  32. Remove the 2 engine mount studs.
  33. Remove the 2 upper engine mount bracket bolts.
    Fig 24: Locating Upper Engine Mount Bracket Bolts
    G06061985Courtesy of FORD MOTOR CO.
  34. Loosen the lower engine mount bracket bolt and remove the engine mount bracket and bolt as an assembly.
    Fig 25: Locating Lower Engine Mount Bracket Bolt
    G06061986Courtesy of FORD MOTOR CO.
  35. Remove the A/C tube bracket bolt.
    Fig 26: Locating A/C Tube Bracket Bolt
    G06061987Courtesy of FORD MOTOR CO.
  36. Remove the A/C tube retaining clamp bolt.
    Fig 27: Locating A/C Tube Retaining Clamp Bolt
    G06061988Courtesy of FORD MOTOR CO.
  37. Remove the A/C tube-to-evaporator bolt and the 2 A/C tubes as an assembly.
    • Discard the O-ring seals.
      Fig 28: Locating A/C Tube-To-Evaporator Bolt And A/C Tubes
      G06061989Courtesy of FORD MOTOR CO.
  38. Using the floor jack, raise the engine slightly.
  39. Remove the 22 engine front cover bolts.
    Fig 29: Locating Engine Front Cover Bolts
    G06061990Courtesy of FORD MOTOR CO.
  40. 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 crisscross pattern until the engine front cover-to-cylinder block seal is released.
      • Remove the engine front cover.
        Fig 30: Locating Engine Front Cover Bolts
        G06061991Courtesy of FORD MOTOR CO.
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