Engine Front Cover: Removal

WARNING: This page is about a different car, the 2018 Ford Edge. However, it is still accessible from the selected car via links, so may be relevant.

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. 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. All parts must be thoroughly cleaned and 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.

With the vehicle in NEUTRAL, position it on a hoist. Refer to: Jacking and Lifting - Overview .
NOTE: Do not pull the engine appearance cover forward or sideways to remove. Failure to press straight upward on the underside of the cover at the attachment points may result in damage to the cover or engine components.
1. Place your hand under the engine appearance cover at each grommet location and push straight up to release each grommet from the studs.
2. After all of the grommets have been released from the studs, remove the appearance cover from the engine.
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Loosen.

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Remove the following items:
1. Refer to: Accessory Drive Belt .
2. Refer to: Accessory Drive Belt Tensioner .
3. Refer to: Brake Vacuum Pump - 2.0L EcoBoost (184kW/250PS) - MI4 .
4. Refer to: Valve Cover .
Remove the bolts and the rear intake camshaft cap.

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Clean the rear intake camshaft cap.

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Using a wrench on the flats of the intake camshaft to prevent cam rotation, remove the brake vacuum pump adapter.

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- Disconnect the CKP sensor electrical connector.
- Remove the 2 bolts and the CKP sensor.
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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.

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Remove the engine plug bolt.

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Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.

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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 removed from graphic for clarity.

Rotate the crankshaft clockwise until the contacts the special tool. Use Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.

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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 Special Service Tool: 303-1565 Alignment Tool, Camshaft.

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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 Crank Damper Holding Tool 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.

Using the special tool, remove the bolt, washer and the crankshaft pulley. Use Special Service Tool: 303-1689 Holding Tool, Crank Damper.

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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.

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Install the old crankshaft pulley bolt.

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NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal.

Using the special tool, remove and discard the crankshaft front seal. Use Special Service Tool: 303-409 (T92C-6700-CH) Remover, Crankshaft Seal.

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Remove and discard the crankshaft pulley bolt.

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Remove the engine mount. Refer to: Engine Mount .
Remove the bolts and the coolant pump pulley.

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Remove the nuts and wiring harness retainer and position the turbocharger vacuum control valve aside.

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Remove the fasteners and the engine front cover.

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Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation .

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