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Home >> Ford >> 2002 >> Cutaway 7.3 F >> Repair and Diagnosis >> External Pages >> Different car >> Section 2436 (Engine - 6.4L 99R Diesel -- F250-F550 Super Duty) >> In-Vehicle Servicing >> Engine Front Cover >> Removal

Engine Front Cover: Removal

WARNING: This page is about a different car, the 2008 Ford Pickup, 2008 Ford F550 Super Duty, 2008 Ford F450 Super Duty, and 2008 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Position a suitable protective material in front of the Charge Air Cooler (CAC) or damage to the CAC may occur.
  1. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING article.
  2. Remove the crankshaft front seal. For additional information, refer to Crankshaft Front Seal .
  3. Remove the retaining nut for the power steering hose and tube.
    4. NOTE: Raise the supply tube up to clear the Engine Coolant Temperature (ECT) sensor connector when positioning the power steering pump aside.
  4. Remove the 3 bolts for the power steering pump. Position the power steering pump aside.
  5. Loosen the clamp and disconnect the vertical EGR cooler coolant hose.
    • Discard the vertical EGR cooler coolant hose clamp.
  6. Remove the 2 retaining nuts for the vertical EGR cooler.
  7. Remove the bolt and the EGR cooler coolant tube.
    • Remove and discard the O-ring seal.
  8. Disconnect the Exhaust Gas Recirculation Temperature (EGRT) sensor electrical connector. Disconnect the hose and retaining clips at the EGR cooler.
  9. Remove the retaining nut and retaining clip.
  10. Remove the nut and bolt for the vertical EGR cooler.
  11. Remove the vertical EGR cooler stud.
    • Remove and discard the gasket.
  12. Remove the 5 bolts and the vertical EGR cooler assembly.
    • Remove and discard the gasket.
  13. Remove the retaining clip and disconnect the lower radiator hose.
  14. Remove the retaining clip and the upper radiator hose.
  15. Remove the 2 bolts and position aside the heater return tube.
    • Remove and discard the O-ring seal.
  16. Remove the 2 bolts and disconnect the EGR cooler coolant supply tube from the front cover.
    • Remove and discard the O-ring seal and the clamp.
  17. Remove the bolt and the accessory drive belt tensioner.
  18. If equipped, remove the bolt and the A/C belt tensioner.
  19. Remove the bolt and the accessory drive belt idler pulley.
  20. Disconnect the ECT sensor electrical connector and wire retainer.
    21. Fig 1: Locating ECT Sensor Electrical Connector & Wire Retainer
    GF0048472Courtesy of FORD MOTOR CO.
  21. Remove the nut and 2 bolts for the heater supply tube and engine wiring harness.
    22. NOTE: Do not bend or flex the heater supply tube or damage to the tube may occur.
  22. Position the heater supply tube as needed so that it will not interfere with the removal of the front cover. Secure the tube as needed.
    • Remove and discard the O-ring seal.
    23. Fig 2: Positioning Heater Supply Tube As Needed So That It Will Not Interfere With Removal Of Front Cover
    GF0048515Courtesy of FORD MOTOR CO.
    NOTE: Remove the thermostat housing only if the front cover is being replaced.
  23. Remove the 4 bolts, collar and the thermostat housing.
    • Remove and discard the press-in-place gasket.
    24. NOTE: Remove the coolant pump pulley only if the front cover is being replaced.
  24. Remove the 4 bolts and the coolant pump pulley.
    25. NOTE: Remove the coolant pump only if the front cover is being replaced.
  25. Remove the 5 bolts and the coolant pump.
    • Discard the O-ring seal.
    26. NOTE: Mark the location of the 4 short bolts to aid in installing the oil pump housing.
  26. Remove the 11 bolts and the oil pump housing.
    • Remove and discard the press-in-place gasket.
    27. NOTE: Mark the front of each drive rotor for correct reassembly orientation.
  27. Remove the inner and outer oil pump drive rotors.
    28. NOTE: Make the location of the front cover fasteners prior to removing them.
  28. Remove the 10 bolts and the engine front cover.
    29. NOTE: Sealant is used where the upper and lower crankcase meet. Failure to cut the sealant may result in pulling the lower crankcase seal out while removing the front cover gasket.
    NOTE: Engine removed for clarity.
  29. Use a thin-blade scraper to cut the sealant where the upper and lower crankcase meet.
    • Remove and discard the front cover gasket.
    30. Fig 3: Using A Thin-Blade Scraper To Cut Sealant Where Upper & Lower Crankcase Meet
    GF0048516Courtesy of FORD MOTOR CO.
  30. Remove the bolt and the EGR coolant adapter.
    • Remove and discard the O-ring seal.
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