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Home >> Ford >> 2019 >> Taurus SHO >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine - 2.0L GTDI >> In-Vehicle Repair >> Engine Front Cover >> Removal

Engine Front Cover: Removal

NOTE: 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 is also unfastened if the pulley bolt is loosened. 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.
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 can cause engine failure.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Jacking And Lifting .
  2. Release the fuel system pressure. For additional information, refer to Fuel System - General Information .
  3. Remove the CAC inlet tube.
    GFD339268Courtesy of FORD MOTOR COMPANY
  4. Loosen the 3 coolant pump pulley bolts.
    GFD339269Courtesy of FORD MOTOR COMPANY
  5. Remove the RH fender splash shield. For additional information, refer to Front End Body Panels .
  6. Remove the accessory drive belt and tensioner. For additional information, refer to Accessory Drive .
  7. Remove the brake vacuum pump. For additional information, refer to Power Brake Actuation - Brake Booster .
  8. Remove the valve cover. For additional information, refer to Valve Cover .
  9. Remove the 2 bolts and the rear intake camshaft cap.
    GFD339270Courtesy of FORD MOTOR COMPANY
  10. Using a wrench on the flats of the intake camshaft to prevent cam rotation, remove the brake vacuum pump adapter.
    GFD339271Courtesy of FORD MOTOR COMPANY
  11. Disconnect the CKP sensor electrical connector.

    • Remove the 2 bolts and the CKP sensor.

    GFD339229Courtesy of FORD MOTOR COMPANY
  12. Turn the crankshaft clockwise until the No. 1 piston is 45 degrees BTDC using the guide holes on the engine front cover and the crankshaft pulley.
    GFD339230Courtesy of FORD MOTOR COMPANY
  13. Remove the 2 bolts, the 2 nuts and the RH halfshaft bracket.

    • Remove the engine plug bolt.

    GFD339231Courtesy of FORD MOTOR COMPANY
  14. Install the Crankshaft TDC Timing Peg.
    GFD339232Courtesy of FORD MOTOR COMPANY
  15. NOTE: The Crankshaft TDC Timing Peg will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during the crankshaft pulley removal and installation.
    NOTE: The engine front cover is shown removed in graphic for clarity.

    Rotate the crankshaft slowly clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg.

    GFD339233Courtesy of FORD MOTOR COMPANY
  16. NOTE: The Camshaft Alignment Tool is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
    NOTE: The camshaft timing slots are offset. If the Camshaft Alignment Tool cannot be installed, remove the TDC Timing Peg and rotate the crankshaft three-fourths of a revolution clockwise and repeat the previous 2 steps of this procedure.

    Install the Camshaft Alignment Tool into the rear of the intake camshaft slot as shown.

    GFD339272Courtesy of FORD MOTOR COMPANY
  17. NOTE: The crankshaft must remain in the TDC position during removal of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the Strap Wrench and the bolt should be removed using an air impact wrench (1/2-in drive minimum).
    NOTE: If equipped, the crankshaft sprocket diamond washer may come off with the crankshaft pulley.

    Use the Crank Damper Holding Tool to hold the crankshaft pulley. Use an air impact wrench to remove the crankshaft pulley bolt.

    • Remove and discard the crankshaft pulley bolt and washer.

    • Remove the crankshaft pulley.

    GFD339236Courtesy of FORD MOTOR COMPANY
  18. NOTE: Early build engines are equipped with a diamond washer on each side of the crankshaft sprocket. Late build engines have a laser etched crankshaft sprocket and do NOT require diamond washers. If an early build engine requires crankshaft sprocket replacement, discard the diamond washers and the sprocket and install a new laser etched sprocket (service part). Diamond washers should NEVER be installed with the laser etched sprocket.

    If equipped, remove the diamond washer.

    GFD339237Courtesy of FORD MOTOR COMPANY
  19. Remove the engine mount. For additional information, refer to Engine Mount .
  20. NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal.

    Using the Oil Seal Remover, remove the crankshaft front oil seal.

    GFD339224Courtesy of FORD MOTOR COMPANY
  21. Remove the 3 bolts and the coolant pump pulley.
    GFD339273Courtesy of FORD MOTOR COMPANY
  22. Remove the nut and the ground strap.

    • Detach the 2 wiring harness retainers from the engine front cover.

    GFD339274Courtesy of FORD MOTOR COMPANY
  23. NOTE: Do not use metal scrapers, wire brushes, power abrasive disks or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.

    Remove the 21 bolts, the stud bolt and the engine front cover.

    GFD339275Courtesy of FORD MOTOR COMPANY
  24. Clean and prepare the RTV sealing surface. For additional information, refer to Engine System - General Information .
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