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Home >> Ford >> 2006 >> Focus ZX5 SE, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1495 (Engine Mechanical - 3.5L) >> Removal >> Engine Front Cover

Engine Front Cover

WARNING: This page is about a different car, the 2011 Lincoln MKZ and 2011 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL(S)

G07784670
 Adjustable Grip Arm, 1735A
014-00001 or equivalent
G07784671
 3 Jaw Puller
303-D121 or equivalent
G07784672
 Handle
205-153 (T80T-4000-W)
G07784673
 Powertrain Lift
300-OTC1585AE
G07784674
 Remover, Oil Seal
303-409 (T92C-6700CH)
G07784675
 Remover, Tie-Rod End
211-105
G07784676
 Remover, VCT Spark Plug Tube Seal
303-1247/1
G07784677
 Strap Wrench
303-D055 (D85L-6000-A) or equivalent
MATERIAL

Item Specification
Motorcraft® Metal Surface Prep
ZC-31-A		 -
Motorcraft® Silicone Gasket Remover
ZC-30		 -
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
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 article.
  2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - FUSION, MILAN & MKZ article.
  3. Recover the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION & DIAGNOSTICS -- FUSION, MILAN & MKZ (EXCEPT HYBRID) article.
  4. Remove the accessory drive belt and the power steering belt. For additional information, refer to ACCESSORY DRIVE - 3.5L -- FUSION & MKZ article.
  5. Remove the LH halfshaft and the intermediate shaft. For additional information, refer to FRONT DRIVE HALFSHAFTS article.
  6. If equipped, remove the 6 screws and the underbody shield.
    Fig 1: Locating Underbody Shield Screws
    G07784678Courtesy of FORD MOTOR CO.
  7. Disconnect the power steering cooler tube and drain the power steering fluid into a suitable drain pan.
    Fig 2: Locating Power Steering Cooler Tube
    G07784679Courtesy of FORD MOTOR CO.
  8. Drain the cooling system. For additional information, refer to ENGINE COOLING SYSTEM (EXCEPT HYBRID) article.
  9. Remove the degas bottle. For additional information, refer to ENGINE COOLING SYSTEM (EXCEPT HYBRID) article.
  10. Remove the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING - 3.5L -- FUSION & MKZ article.
  11. Remove the battery tray. For additional information, refer to BATTERY, MOUNTING & CABLES -- FUSION, MILAN & MKZ article.
  12. Disconnect the 2 engine wiring harness electrical connectors.
    Fig 3: Locating Engine Wiring Harness Electrical Connectors
    G07784680Courtesy of FORD MOTOR CO.
  13. Detach the 2 wiring harness retainers from transmission mount and the battery tray bracket.
    Fig 4: Locating Wiring Harness Retainers At Transmission Mount And Battery Tray Bracket
    G07784681Courtesy of FORD MOTOR CO.
  14. Remove the 2 nuts and the battery cables from the positive battery cable.
    Fig 5: Locating Nuts, Battery Cables And Positive Battery Cable
    G07784682Courtesy of FORD MOTOR CO.
  15. Remove the bolt and position aside the ground wire.
    Fig 6: Identifying Ground Wire Bolt
    G07784683Courtesy of FORD MOTOR CO.
  16. Disconnect the vacuum hose and the Evaporative Emission (EVAP) tube from the upper intake manifold.
    Fig 7: Locating Vacuum Hose And Evaporative Emission (EVAP) Tube
    G07784684Courtesy of FORD MOTOR CO.
  17. Disconnect the upper radiator hose, lower radiator hose and 2 heater hoses from the thermostat housing.
    Fig 8: Locating Upper Radiator Hose, Lower Radiator Hose And Heater Hoses
    G07784685Courtesy of FORD MOTOR CO.
  18. Disconnect the transaxle control cable from the control lever.
    Fig 9: Locating Transaxle Control Cable At Control Lever
    G07784686Courtesy of FORD MOTOR CO.
  19. Remove the 3 nuts and position the transaxle control cable bracket aside.
    Fig 10: Locating Transaxle Control Cable Bracket Nuts
    G07784687Courtesy of FORD MOTOR CO.
  20. Remove the bolt and position the ground wire aside.
    Fig 11: Locating Ground Wire And Bolt
    G07784688Courtesy of FORD MOTOR CO.
  21. If equipped, detach the engine block heater harness from the radiator support, power steering hose, A/C tube and the engine wiring harness.
  22. Detach the coolant tube retainer clips from the A/C tube.
    Fig 12: Locating Coolant Tube Retainer Clips On A/C Tube
    G07784689Courtesy of FORD MOTOR CO.
  23. Remove the nut and disconnect the A/C tube from the condenser.
    • Discard the O-ring seals.
    Fig 13: Locating A/C Tube Nut
    G07784690Courtesy of FORD MOTOR CO.
  24. Remove the 2 A/C tube retaining clamp bolts.
    Fig 14: Locating A/C Tube Bracket Bolts
    G07784691Courtesy of FORD MOTOR CO.
  25. Remove the A/C tube bracket bolt.
    Fig 15: Locating A/C Tube Bracket Bolt
    G07784692Courtesy of FORD MOTOR CO.
  26. Remove the 2 nuts and disconnect the A/C tubes.
    • Discard the O-ring seals.
    Fig 16: Locating A/C Tubes Nuts
    G07784693Courtesy of FORD MOTOR CO.
  27. Detach the 2 wiring harness retainers.
    Fig 17: Locating Wiring Harness Retainers
    G07784694Courtesy of FORD MOTOR CO.
  28. Disconnect the 2 engine wiring harness electrical connectors.
    Fig 18: Locating Engine Control Wiring Harness Electrical Connectors
    G07784695Courtesy of FORD MOTOR CO.
  29. Remove the 2 wiring harness retainers from the LH valve cover stud bolts and position the wiring harness aside.
    Fig 19: Locating Wiring Harness Retainers At LH Valve Cover Stud Bolts
    G07784696Courtesy of FORD MOTOR CO.
  30. Remove the oil level indicator.
    Fig 20: Identifying Oil Level Indicator
    G07784697Courtesy of FORD MOTOR CO.
  31. Disconnect the hose from the power steering reservoir.
    • Detach the pin-type retainer from the engine mount brace.
    Fig 21: Locating Pin-Type Retainer At Engine Mount Brace
    G07784698Courtesy of FORD MOTOR CO.
  32. Using a small screwdriver, release the retaining clip and detach the power steering reservoir from the cowl.
    Fig 22: Removing Power Steering Reservoir Retaining Clip Using Small Screwdriver
    G07784699Courtesy of FORD MOTOR CO.
  33. Disconnect the fuel supply tube from the fuel rail. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - FUSION, MILAN & MKZ article.
    Fig 23: Locating Fuel Supply Tube
    G07784700Courtesy of FORD MOTOR CO.
  34. Remove the bolt and the ground wire from the engine mount brace.
    Fig 24: Locating Bolt And Ground Wire On Engine Mount Brace
    G07784701Courtesy of FORD MOTOR CO.
  35. Remove the 3 bolts and the engine mount brace.
    Fig 25: Identifying Bolts And Engine Mount Brace
    G07784702Courtesy of FORD MOTOR CO.
  36. Disconnect the PCM electrical connectors and pin-type retainers.
    Fig 26: Locating PCM Electrical Connectors And Pin-Type Retainers
    G07784703Courtesy of FORD MOTOR CO.
  37. Remove the Power Steering Pressure (PSP) hose bracket bolt.
    Fig 27: Locating Power Steering Pressure Hose Bracket Bolt
    G07784704Courtesy of FORD MOTOR CO.
  38. Remove and discard the PSP banjo bolt and the 2 seals from the steering gear.
    Fig 28: Locating PSP Hose Banjo Bolt
    G07784705Courtesy of FORD MOTOR CO.
    39. NOTE: Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent).
    Fig 29: Holding Steering Wheel In Straight-Ahead Position Using Suitable Holding Device
    G07784706Courtesy of FORD MOTOR CO.
  39. Using a suitable holding device, hold the steering wheel in the straight-ahead position.
  40. Remove the 2 nuts and the steering joint cover.
    Fig 30: Locating Nuts And Steering Joint Cover
    G07784707Courtesy of FORD MOTOR CO.
    41. NOTE: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring may occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to SUPPLEMENTAL RESTRAINT SYSTEM -- FUSION, MILAN & MKZ article.
    NOTE: Index-mark the steering column shaft position to the steering gear for reference during installation.
    Fig 31: Locating Steering Column Shaft Position Mark And Bolt
    G07784708Courtesy of FORD MOTOR CO.
  41. Remove the bolt and disconnect the steering column shaft from the steering gear.
    • Discard the bolt.
  42. Remove the 4 screws and position the LH fender splash shield aside.
    Fig 32: Locating LH Fender Splash Shield Screws
    G07784709Courtesy of FORD MOTOR CO.
  43. Remove the 6 pin-type retainers (4 shown in illustration) and the LH splash shield.
    Fig 33: Locating Pin-Type Retainers And LH Splash Shield
    G07784710Courtesy of FORD MOTOR CO.
    44. NOTE: The steering gear-to-dash seal must be removed or it will be damaged when lowering the subframe.
    Fig 34: Locating Clips And Steering Gear-To-Dash Seal
    G07784711Courtesy of FORD MOTOR CO.
  44. Release the 4 clips and slide the steering gear-to-dash seal off of the steering gear and into the passenger compartment.
  45. Disconnect the transaxle cooler hoses.
    Fig 35: Locating Transaxle Cooler Hoses
    G07784712Courtesy of FORD MOTOR CO.
  46. Remove the drain plug and drain the engine oil.
    • Install the drain plug and tighten to 27 Nm (20 lb-ft).
    Fig 36: Identifying Engine Drain Plug
    G07784713Courtesy of FORD MOTOR CO.
  47. Remove and discard the engine oil filter.
  48. Remove the 6 nuts and the Y-pipe assembly.
    • Discard the gaskets and nuts.
    Fig 37: Locating Nuts And Y-Pipe Assembly
    G07784714Courtesy of FORD MOTOR CO.

    All-Wheel Drive (AWD) vehicles 

    49. NOTE: Index-mark the driveshaft for installation.
    Fig 38: Locating Driveshaft Bolts
    G07784715Courtesy of FORD MOTOR CO.
  49. Remove and discard the 4 bolts (3 shown in illustration) and support the driveshaft with a length of mechanic's wire.

    All vehicles 

  50. Remove the engine roll restrictor-to-subframe through bolt.
    Fig 39: Locating Engine Roll Restrictor-To-Subframe Through Bolt
    G07784716Courtesy of FORD MOTOR CO.
    51. NOTE: LH shown in illustration, RH similar.
    Fig 40: Locating Tie-Rod End Nut And Cotter Pin
    G07784717Courtesy of FORD MOTOR CO.
  51. Remove the cotter pins and nuts from the tie-rod ends.
    52. NOTE: LH shown in illustration, RH similar.
    Fig 41: Separating Tie-Rod Ends From Steering Knuckles Using Tie-Rod End Remover
    G07784718Courtesy of FORD MOTOR CO.
  52. Using the Tie-Rod End Remover, separate the tie-rod ends from the steering knuckles.
    53. NOTE: LH shown in illustration, RH similar.
    Fig 42: Locating Stabilizer Bar Link Nut
    G07784719Courtesy of FORD MOTOR CO.
  53. Remove the nuts and separate the stabilizer bar links from the struts.
  54. Using a wax pencil, mark the relationship of the front subframe to the underbody at the mounting locations.
  55. Position the Powertrain Lift under the subframe assembly.
    Fig 43: Positioning Powertrain Lift Under Subframe Assembly
    G07784720Courtesy of FORD MOTOR CO.
    56. NOTE: LH shown in illustration, RH similar.
    Fig 44: Locating Subframe Bracket-To-Body Bolts
    G07784721Courtesy of FORD MOTOR CO.
  56. Remove the 4 subframe bracket-to-body bolts.
    57. NOTE: LH shown in illustration, RH similar.
    Fig 45: Locating Rear Subframe Nut And Subframe Bracket
    G07784722Courtesy of FORD MOTOR CO.
  57. Remove the 2 subframe nuts and the 2 subframe brackets.
    58. NOTE: LH shown in illustration, RH similar.
    Fig 46: Locating Front Subframe Nut
    G07784723Courtesy of FORD MOTOR CO.
  58. Remove the 2 front subframe nuts.
  59. Using the Powertrain Lift, lower the subframe assembly from the vehicle.
    Fig 47: Identifying Powertrain Lift Under Subframe Assembly
    G07784724Courtesy of FORD MOTOR CO.

    Front Wheel Drive (FWD) vehicles 

  60. Remove the 2 RH catalytic converter bracket bolts.
    Fig 48: Locating RH Catalytic Converter Bracket Bolts
    G07784725Courtesy of FORD MOTOR CO.
  61. Remove the 2 nuts and remove the RH catalytic converter bracket.
    Fig 49: Locating Nuts And RH Catalytic Converter Bracket
    G07784726Courtesy of FORD MOTOR CO.

    All vehicles 

    62. NOTE: Position a block of wood under the transaxle.
    Fig 50: Installing Powertrain Lift And Adjustable Grip Arms
    G07784727Courtesy of FORD MOTOR CO.
  62. Install the Powertrain Lift and Adjustable Grip Arms.
  63. Remove the transaxle support insulator through bolt.
    Fig 51: Locating Transaxle Support Insulator Through Bolt And Nut
    G07784728Courtesy of FORD MOTOR CO.
  64. Remove the transaxle support insulator bracket bolt and the 2 nuts.
    Fig 52: Locating Transaxle Support Insulator Bracket Bolt And Nuts
    G07784729Courtesy of FORD MOTOR CO.
  65. Remove the 4 engine mount nuts.
    • Remove the 2 engine mount spacers.
    Fig 53: Locating Engine Mount Nuts
    G07784730Courtesy of FORD MOTOR CO.
  66. Remove the nut, 2 bolts and the engine mount.
    Fig 54: Locating Engine Mount Nut And Bolts
    G07784731Courtesy of FORD MOTOR CO.
  67. Lower the engine and transaxle assembly from the vehicle.
  68. If equipped, detach the block heater wiring harness retainer from the upper intake manifold.
    Fig 55: Locating Block Heater Wiring Harness Retainer At Upper Intake Manifold
    G07784732Courtesy of FORD MOTOR CO.
  69. If equipped, detach the block heater wiring harness retainers from the PSP hose and the power steering reservoir hose.
    Fig 56: Locating Block Heater Wiring Harness Retainers At PSP Hose And Power Steering Reservoir Hose
    G07784733Courtesy of FORD MOTOR CO.
  70. Disconnect the PCV hose from the PCV valve.
    Fig 57: Locating PCV Hose
    G07784734Courtesy of FORD MOTOR CO.
  71. Disconnect the Throttle Body (TB) electrical connector.
    Fig 58: Locating Throttle Body (TB) Electrical Connector
    G07784735Courtesy of FORD MOTOR CO.
  72. Detach the wiring harness retainers from the upper intake manifold.
    Fig 59: Locating Wiring Harness Retainers At Upper Intake Manifold
    G07784736Courtesy of FORD MOTOR CO.
  73. Remove the upper intake manifold support bracket bolt.
    Fig 60: Locating Upper Intake Manifold Support Bracket Bolt
    G07784737Courtesy of FORD MOTOR CO.
    74. NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
    Fig 61: Locating Upper Intake Manifold Bolts
    G07784738Courtesy of FORD MOTOR CO.
  74. Remove the 6 bolts and the upper intake manifold.
    • Discard the gaskets.
  75. Disconnect the RH Catalyst Monitor Sensor (CMS) electrical connector.
    Fig 62: Identifying RH Catalyst Monitor Sensor Electrical Connector
    G07784739Courtesy of FORD MOTOR CO.
  76. Disconnect the PSP switch electrical connector.
    Fig 63: Locating PSP Switch Electrical Connector
    G07784740Courtesy of FORD MOTOR CO.
  77. Disconnect the RH VCT solenoid electrical connector.
    Fig 64: Locating RH Variable Camshaft Timing (VCT) Solenoid Electrical Connector
    G07784741Courtesy of FORD MOTOR CO.
  78. Disconnect the 3 RH coil-on-plug electrical connectors.
    Fig 65: Locating RH Coil-On-Plug Electrical Connectors
    G07784742Courtesy of FORD MOTOR CO.
  79. Detach all of the wiring harness retainers from the RH valve cover and stud bolts.
  80. Disconnect the LH VCT solenoid electrical connector.
    Fig 66: Locating LH VCT Solenoid Electrical Connector
    G07784743Courtesy of FORD MOTOR CO.
  81. Disconnect the 3 LH coil-on-plug electrical connectors.
    Fig 67: Locating LH Coil-On-Plug Electrical Connectors
    G07784744Courtesy of FORD MOTOR CO.
  82. Detach all of the wiring harness retainers from the LH valve cover and stud bolts.
    83. NOTE: LH shown in illustration, RH similar.
    Fig 68: Locating Coil-On-Plugs And Bolts
    G07784745Courtesy of FORD MOTOR CO.
  83. Remove the 6 bolts and the 6 coil-on-plugs.
  84. Detach the PSP hose retainer from the engine lifting eye.
    Fig 69: Locating PSP Hose Retainer At Engine Lifting Eye
    G07784746Courtesy of FORD MOTOR CO.
  85. Remove the PSP hose bracket nut and position the PSP hose aside.
    Fig 70: Locating PSP Hose Bracket Nut
    G07784747Courtesy of FORD MOTOR CO.
  86. Remove the 2 nuts and the wiring harness retaining bracket.
    Fig 71: Locating Nuts And Wiring Harness Retaining Bracket
    G07784748Courtesy of FORD MOTOR CO.
  87. Loosen the 9 stud bolts and remove the LH valve cover.
    • Discard the gasket.
    Fig 72: Locating LH Valve Cover Stud Bolts
    G07784749Courtesy of FORD MOTOR CO.
  88. Loosen the bolt, the 8 stud bolts and remove the RH valve cover.
    • Discard the gasket.
    Fig 73: Locating RH Valve Cover Bolts
    G07784750Courtesy of FORD MOTOR CO.
    89. NOTE: VCT solenoid seal removal shown in illustration, spark plug tube seal removal similar.
    Fig 74: Removing Seal Using VCT Spark Plug Tube Seal Remover And Handle
    G07784751Courtesy of FORD MOTOR CO.
  89. Inspect the VCT solenoid seals and the spark plug tube seals. Install new seals if damaged.
    • Using the VCT Spark Plug Tube Seal Remover and Handle, remove the seal(s).
  90. Remove the 3 bolts and the accessory drive belt tensioner.
    Fig 75: Locating Accessory Drive Belt Tensioner Bolts
    G07784753Courtesy of FORD MOTOR CO.
  91. Using the Strap Wrench, remove the crankshaft pulley bolt and washer.
    • Discard the bolt.
    Fig 76: Identifying Crankshaft Pulley Bolt And Washer With Strap Wrench
    G07784754Courtesy of FORD MOTOR CO.
  92. Using the 3 Jaw Puller, remove the crankshaft pulley.
    Fig 77: Removing Crankshaft Pulley Using Jaw Puller
    G07784755Courtesy of FORD MOTOR CO.
  93. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
    Fig 78: Removing Crankshaft Front Seal Using Oil Seal Remover
    G07784756Courtesy of FORD MOTOR CO.
  94. Remove the 2 bolts and the engine mount bracket.
    Fig 79: Locating Engine Mount Bracket And Bolts
    G07784757Courtesy of FORD MOTOR CO.
    95. NOTE: Only use hand tools to remove the studs.
    Fig 80: Locating Engine Mount Studs
    G07784758Courtesy of FORD MOTOR CO.
  95. Remove the 2 engine mount studs.
  96. Remove the 3 bolts and the engine mount bracket.
    Fig 81: Locating Engine Mount Bracket And Bolts
    G07784759Courtesy of FORD MOTOR CO.
  97. Remove the 22 engine front cover bolts.
    Fig 82: Locating Engine Front Cover Bolts
    G07784760Courtesy of FORD MOTOR CO.
  98. Install 6 of the engine front cover bolts (finger-tight) into the 6 threaded holes in the engine front cover in the following sequence.
    1. Tighten the bolts one turn at a time in a crisscross pattern until the engine front cover-to-cylinder block seal is released.
    2. Remove the engine front cover.
    Fig 83: Identifying Engine Front Cover Bolts
    G07784761Courtesy of FORD MOTOR CO.
    99. NOTE: Only use a 3M Roloc® Bristle Disk (2-in white, part number 07528) to clean the engine front cover. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean the engine front cover.
  99. Clean the engine front cover using a 3M Roloc® Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15,000 rpm.
    • Thoroughly wash the engine front cover to remove any foreign material, including any abrasive particles created during the cleaning process.
    100. NOTE: Place clean, lint-free shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.
    NOTE: Do not use wire brushes, power abrasive discs or 3M™ Roloc® Bristle Disk (2-in white, part number 07528) to clean the sealing surfaces of the engine block, cylinder heads, and oil pan. These tools cause contamination that can cause premature engine failure. Remove all traces of sealant, including any sealant from the inner surface of the cylinder block and cylinder head.
  100. Clean all engine sealing surfaces, including the cylinder heads, the oil pan and cylinder block in the following sequence.
    1. Remove any large deposits of silicone or gasket material.
    2. Apply silicone gasket remover and allow to set for several minutes.
    3. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
    4. Apply metal surface prep to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
    5. Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
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