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Home >> Ford >> 2018 >> Fusion Platinum, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 18 (Engine - 2.7L ECOBOOST (238KW/324PS)) >> Removal And Installation >> Engine Front Cover >> Removal

Engine Front Cover: Removal

WARNING: This page is about a different variant/trim than selected.
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. Refer to : Jacking and Lifting - Overview .
  2. Disconnect the battery ground cable. Refer to : Battery Disconnect and Connect .
  3. Remove and discard the engine oil filter and drain the engine oil. Refer to : Engine Oil Draining and Filling .
  4. Drain the engine cooling system. Refer to : Cooling System Draining, Vacuum Filling and Bleeding .
  5. Remove the following items:

    1. NOTE: It is not necessary to clamp off the degas bottle hose with the cooling system drained.

      Refer to: Degas Bottle .

    2. Refer to: Powertrain Control Module (PCM) .
    3. Refer to: Valve Cover LH .
    4. Refer to: Valve Cover RH .
    5. RH fender splash shield. Refer to : Fender Splash Shield .
    6. Refer to: Accessory Drive Belt Tensioner .
    7. Refer to: Oil Pressure Control Solenoid .

  6. Remove the generator nut.
    GFD192383Courtesy of FORD MOTOR COMPANY
  7. Position the A/C line bracket from the generator stud.
    GFD192666Courtesy of FORD MOTOR COMPANY
  8. Detach the wiring harness retainers, slide up the insulator and disconnect the A/C compressor electrical connectors.
    GFD192667Courtesy of FORD MOTOR COMPANY
    1. Remove the nut.
    2. Remove the stud.
    3. Remove the bolt.
    4. Remove the stud bolt and position the A/C compressor aside and support with a length of mechanics wire.
    Fig 1: A/C Compressor Bolts Loosening Sequence
    GFD192668Courtesy of FORD MOTOR COMPANY
    1. Remove the M8 x 50mm bolt.
    2. Remove the M10 x 43mm bolt.
    3. Remove the M8 x 30mm bolt and the A/C compressor mounting bracket.
    GFD192385Courtesy of FORD MOTOR COMPANY
  11. Remove the bolt and the idler pulley.
    GFD192436Courtesy of FORD MOTOR COMPANY
  12. Remove the bolt, the stud and position the generator aside.
    GFD192437Courtesy of FORD MOTOR COMPANY
  13. Remove the oil level indicator.
    GFD192360Courtesy of FORD MOTOR COMPANY
  14. Support the cooling module.
    GFD192355Courtesy of FORD MOTOR COMPANY
  15. If equipped, remove the retainers and the front underbody straps.
    GFD192357Courtesy of FORD MOTOR COMPANY
  16. Remove the retainers and the underbody shields.
    GFD192358Courtesy of FORD MOTOR COMPANY
  17. Remove the RH ride height sensor. Refer to : Front Suspension Height Sensor .
  18. NOTE: Use the internal or external hex-holding feature to prevent the ball and stud from turning while removing or installing the stabilizer bar link nuts. The link boot seal must not be allowed to twist while tightening the link nuts or damage to the boot seal will occur.

    Remove the nut and position the RH sway bar link aside.

    GFD192389Courtesy of FORD MOTOR COMPANY
  19. Remove the nuts and the subframe support bracket.
    GFD192390Courtesy of FORD MOTOR COMPANY
  20. Mark the subframe location.
    GFD192395Courtesy of FORD MOTOR COMPANY
  21. Mark the subframe location.
    GFD192396Courtesy of FORD MOTOR COMPANY
  22. Position adjustable stands under the sides of the subframe. Use the General Equipment: Vehicle/Axle Stands
    GFD192669Courtesy of FORD MOTOR COMPANY
  23. NOTE: Make sure the cooling module is secure.

    Remove the fasteners and the cooling module support panel.

    GFD192397Courtesy of FORD MOTOR COMPANY
  24. NOTE: The original subframe fasteners will be used later in this procedure, do not discard the bolts until instructed to in this procedure.

    1. Remove the subframe bolts.
    2. Remove the bolts and the subframe brackets.

    GFD192533Courtesy of FORD MOTOR COMPANY
  25. Remove the subframe bolts.
    GFD192670Courtesy of FORD MOTOR COMPANY
  26. Using the adjustable stands lower the LH side of the subframe 20 mm (0. 75 in) and lower the RH 65 mm (2. 5 in). Use the General Equipment: Vehicle/Axle Stands
    GFD192671Courtesy of FORD MOTOR COMPANY
  27. Remove the oil pan bolts.
    GFD192672Courtesy of FORD MOTOR COMPANY
  28. Using a large flat-bladed screwdriver and the indicated pry pads, release the sealer and separate the oil pan from the bottom of the engine. Use the General Equipment: Flat-Bladed Screwdriver
    GFD192673Courtesy of FORD MOTOR COMPANY
  29. NOTE: Suspension components and jackstand removed from graphic for clarity.

    1. Rotate the front of the oil pan slightly toward the front of the vehicle.
    2. Position the front of the oil pan to the RH side of the vehicle above the subframe.
    3. Lower the rear of the oil pan to clear the exhaust and remove the oil pan.
    4. NOTE: Do not re Use the oil pan.

      Discard the oil pan.

    GFD192674Courtesy of FORD MOTOR COMPANY
  30. Remove and discard the oil pump seal.
    GFD192393Courtesy of FORD MOTOR COMPANY
  31. NOTE: Do not Use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove traces of sealant.

    Make sure that the oil pan sealing surfaces of the cylinder block and engine front cover are free of foreign material. Refer to : RTV Sealing Surface Cleaning and Preparation . Use the General Equipment: Plastic Scraper

    Material: Motorcraft ® Silicone Gasket Remover / ZC-30-A

    Material: Motorcraft ® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

    Material: Motorcraft ® Metal Surface Prep Wipes / ZC-31-B

    GFD192394Courtesy of FORD MOTOR COMPANY
  32. Using the adjustable stands, raise the subframe into the installed position. Use the General Equipment: Vehicle/Axle Stands
    GFD192675Courtesy of FORD MOTOR COMPANY
  33. Install the original subframe bolts.
    GFD192676Courtesy of FORD MOTOR COMPANY
    1. Install the subframe brackets and the original subframe bolts.
    2. Install the subframe bracket bolts.
    GFD192533Courtesy of FORD MOTOR COMPANY
  35. Remove the stands. Remove the General Equipment: Vehicle/Axle Stands
    GFD192677Courtesy of FORD MOTOR COMPANY
  36. Remove the retainers and the splash shield.
    GFD192678Courtesy of FORD MOTOR COMPANY
  37. Detach the wiring harness retainers.
    GFD192421Courtesy of FORD MOTOR COMPANY
    1. Release the clamp and disconnect the lower radiator hose. Use the General Equipment: Hose Clamp Remover/Installer
    2. Release the clamp and disconnect the heater hose. Use the General Equipment: Hose Clamp Remover/Installer
    3. Detach the heater hose retainer.
    4. Remove the bolt and position the heater hose aside.
    GFD192373Courtesy of FORD MOTOR COMPANY
  39. NOTE: Failure to position the wood block and floor jack as illustrated can result in damage to the oil pump. The floor jack will be Use d to lower and raise the engine during the remainder of the removal procedure.

    Support the engine with a floor jack and a wooden block placed under the engine block skirt stiffener. Use the General Equipment: Wooden Block Use the General Equipment: Trolley Jack

    GFD192679Courtesy of FORD MOTOR COMPANY
    1. Remove and discard the engine mount-to-engine nuts.
    2. Remove and discard the engine mount-to-frame nut.
    3. Remove and discard the engine mount-to-frame bolts.
    4. Remove the engine mount.
    GFD192403Courtesy of FORD MOTOR COMPANY
  41. Remove the bolts and the coolant pump pulley.
    GFD192442Courtesy of FORD MOTOR COMPANY
  42. Remove the bolts and the coolant pump.
    GFD192443Courtesy of FORD MOTOR COMPANY
    • Inspect the coolant pump gasket and replace if necessary.

    • NOTE: The grommet may remain in the coolant pump housing. If this occurs, remove the grommet from the coolant pump housing.

      Remove the grommet from the coolant inlet pipe. Inspect the grommet and replace if necessary.

    GFD192680Courtesy of FORD MOTOR COMPANY
  44. Using the floor jack, lower the front of the engine to access the crankshaft pulley. Use the General Equipment: Wooden Block Use the General Equipment: Trolley Jack
    GFD192681Courtesy of FORD MOTOR COMPANY
  45. Remove the crankshaft pulley bolt.
    GFD192438Courtesy of FORD MOTOR COMPANY
  46. Using the 3 Leg Puller and a step plate, remove the crankshaft pulley. Use the General Equipment: Three Leg Puller
    GFD192439Courtesy of FORD MOTOR COMPANY
  47. NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal.

    1. Install the crankshaft pulley bolt.
    2. Using the special tool, remove and discard the crankshaft front oil seal. Use Special Service Tool: 303-409 (T92C-6700-CH) Remover, Crankshaft Seal.
    3. NOTE: If further disassembly of the engine will be performed, retain the original crankshaft pulley bolt for turning the crankshaft while the pulley is removed.

      Remove and discard the crankshaft pulley bolt.

    GFD192682Courtesy of FORD MOTOR COMPANY
  48. Remove the fasteners and the insulator.
    GFD192441Courtesy of FORD MOTOR COMPANY
  49. NOTE: The coolant hoses and wiring harness must be positioned aside to provide a clear extraction path for the engine front cover.

    Secure the coolant hoses and wiring harness aside.

    GFD192683Courtesy of FORD MOTOR COMPANY
  50. NOTE: There are 4 different types of fasteners, note location of each fastener for assembly.

    Remove the engine front cover fasteners.

    GFD192447Courtesy of FORD MOTOR COMPANY
  51. Using a large flat-bladed screwdriver and the indicated pry pads, release the sealer and remove the engine front cover. Use the General Equipment: Flat-Bladed Screwdriver
    GFD192448Courtesy of FORD MOTOR COMPANY
  52. Remove and discard the engine front cover gaskets.
    GFD192449Courtesy of FORD MOTOR COMPANY
  53. Remove and discard the oil gallery seal (6G068).
    GFD192450Courtesy of FORD MOTOR COMPANY
  54. 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 front cover.

    • 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. Refer to : RTV Sealing Surface Cleaning and Preparation .

    • Thoroughly wash the engine front cover to remove any foreign material, including any abrasive particles created during the cleaning process.

      Material: Motorcraft ® Silicone Gasket Remover / ZC-30-A

      Material: Motorcraft ® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

      Material: Motorcraft ® Metal Surface Prep Wipes / ZC-31-B

    GFD192451Courtesy of FORD MOTOR COMPANY
  55. 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 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. These tools cause scratches and gouges that make leak paths. They also cause contamination that will cause premature engine failure. Remove all traces of the gasket.

    Make sure that the mating faces of the engine block are clean and free of foreign material. Refer to : RTV Sealing Surface Cleaning and Preparation . Use the General Equipment: Plastic Scraper

    Material: Motorcraft ® Silicone Gasket Remover / ZC-30-A

    Material: Motorcraft ® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

    Material: Motorcraft ® Metal Surface Prep Wipes / ZC-31-B

    GFD192452Courtesy of FORD MOTOR COMPANY
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