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Home >> Ford >> 2021 >> Explorer Limited Hybrid, 4WD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 16 (Engine - 2.3L ECOBOOST (201KW/273PS)) >> Removal And Installation >> Engine Front Cover >> Removal

Engine Front Cover: Removal

WARNING: This page is about a different variant/trim than selected.
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.
  1. With the vehicle in NEUTRAL, position it on a hoist. Refer to: Jacking and Lifting - Overview .
  2. Remove the bolts and the suspension support bar.
    GFD510466Courtesy of FORD MOTOR COMPANY
  3. 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. Remove the engine appearance cover nuts.
    2. Place your hand under the engine appearance cover at the grommet location and push straight up to release the grommet from the stud.
    3. After the grommet has been released from the stud, remove the appearance cover from the engine.

    GFD510467Courtesy of FORD MOTOR COMPANY
  4. Release the fuel system pressure. Refer to: Fuel System Pressure Release .
  5. Disconnect the battery ground cable. Refer to: BATTERY CABLES - 2.3L ECOBOOST (201KW 273PS) .
  6. Remove the following items:

    1. Remove the air cleaner. Refer to: Air Cleaner .
    2. Remove the air cleaner outlet. Refer to: Air Cleaner Outlet Pipe .
    3. Remove the EVAP canister purge valve. Refer to: Evaporative Emission Canister Purge Valve .

  7. Disconnect the EVAP canister tube quick release coupling and the retainer and remove. Refer to: QUICK RELEASE COUPLING - 2.3L .
    GFD510523Courtesy of FORD MOTOR COMPANY
  8. Remove the air cleaner inlet tube.
    GFD510468Courtesy of FORD MOTOR COMPANY
    • Detach the coolant hose retainer.

    • Detach the wiring harness retainer.

    • Remove the bolts and the air cleaner bracket.

    GFD510524Courtesy of FORD MOTOR COMPANY
  10. Loosen the coolant pump pulley bolts.
    GFD510525Courtesy of FORD MOTOR COMPANY
  11. Remove the following items:

    1. Remove the accessory drive belt. Refer to: Accessory Drive Belt .
    2. Remove the accessory drive belt tensioner. Refer to: Accessory Drive Belt Tensioner .
    3. Remove the high-pressure fuel pump drive unit. Refer to: High-Pressure Fuel Pump Drive Unit .

    • Remove pin-type retainer.

    • Remove the bolts and the underbody shield.

    GFD510470Courtesy of FORD MOTOR COMPANY
  13. Remove the pin-type retainers, bolts and the rear underbody shield.
    GFD510498Courtesy of FORD MOTOR COMPANY
    • Disconnect the CKP sensor electrical connector.

    • Remove the bolts and the CKP sensor.

    GFD510471Courtesy of FORD MOTOR COMPANY
  15. 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.
    GFD510472Courtesy of FORD MOTOR COMPANY
  16. Remove the engine plug bolt.
    GFD510473Courtesy of FORD MOTOR COMPANY
  17. Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.
    GFD510448Courtesy of FORD MOTOR COMPANY
  18. 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.

    GFD510474Courtesy of FORD MOTOR COMPANY
  19. 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: 303-1685 Alignment Tool, Camshaft.

    GFD510526Courtesy of FORD MOTOR COMPANY
  20. 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).

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

    • NOTE: If necessary, retain the original crankshaft pulley bolt to use for the removal of the crankshaft front seal.

      Discard the bolt.

    GFD510527Courtesy of FORD MOTOR COMPANY
  21. Install the old crankshaft pulley bolt.
    GFD510459Courtesy of FORD MOTOR COMPANY
  22. 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.

    GFD510460Courtesy of FORD MOTOR COMPANY
  23. NOTE: If necessary, retain the original crankshaft pulley bolt to use in other procedures.

    Remove and discard the crankshaft pulley bolt.

    GFD510461Courtesy of FORD MOTOR COMPANY
  24. Remove the bolts and the coolant pump pulley.
    GFD510528Courtesy of FORD MOTOR COMPANY
  25. Detach wiring harness retainers from the engine front cover and stud bolts.
    GFD510529Courtesy of FORD MOTOR COMPANY
  26. Remove the fasteners and the engine front cover.
    GFD510530Courtesy of FORD MOTOR COMPANY
  27. NOTE: Only use a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15, 000 rpm, to clean the engine front cover. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean. These tools cause scratches and gouges that make leak paths.

    • Make sure that the mating faces of the engine front cover are clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation .

      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

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

    GFD510531Courtesy of FORD MOTOR COMPANY
  28. 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 metal scrapers, 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 and oil pan 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

GFD510532Courtesy of FORD MOTOR COMPANY
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