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Engine Front Cover: Removal

WARNING: This page is about a different car, the 2006 Mercury Mariner and 2006 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION:
  1. 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 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.
  2. 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 & LIFTING .
  2. Remove the accessory drive belt and idler pulleys. For additional information, refer to REMOVAL AND INSTALLATION - ACCESSORY DRIVE BELT and REMOVAL AND INSTALLATION - IDLER PULLEYS .
  3. Remove the crankshaft pulley. For additional information, refer to CRANKSHAFT PULLEY .
  4. Remove the engine mount. For additional information, refer to ENGINE MOUNT .
    5. CAUTION: Use care not to damage the engine front cover or the crankshaft when removing the seal.
    Fig 1: Removing Crankshaft Front Oil Seal Using Special Tool (303-409)
    G04617928Courtesy of FORD MOTOR CO.
  5. Using the special tool, remove the crankshaft front oil seal.
  6. Remove the 3 bolts and the coolant pump pulley.
  7. Remove the 2 power steering pump bolts.
    Fig 2: Locating Power Steering Pump Bolts
    G03897741Courtesy of FORD MOTOR CO.
    8. NOTE: The bolt under the power steering pressure tube will remain with the power steering pump.
    Fig 3: Identifying Power Steering Pump Bolts
    G03897742Courtesy of FORD MOTOR CO.
  8. Remove the remaining bolts and position the power steering pump aside.
  9. Disconnect the crankshaft position (CKP) sensor electrical connector.
    10. NOTE: Whenever the CKP sensor is removed, a new one must be installed, using the alignment tool supplied with the new part.
  10. Remove and discard the CKP sensor.
  11. Remove the bolts and the engine front cover.
    Fig 4: Locating Engine Front Cover Bolts
    G03897743Courtesy of FORD MOTOR CO.
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