LEMON Manuals: Even more car manuals for everyone
Home >> Mercury >> 2009 >> Mariner Base, 2.5 7, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 79 (Engine Mechanical - 5.4L (4V)) >> In-Vehicle Servicing >> Engine Front Cover >> Removal

Engine Front Cover: Removal

WARNING: This page is about a different car, the 2009 Ford Mustang. However, it is still accessible from the selected car via links, so may be relevant.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING .
  2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
  3. Remove the engine coolant degas bottle. For additional information, refer to ENGINE COOLING .
  4. Remove the Supercharger (SC) coolant degas bottle. For additional information, refer to SUPERCHARGER COOLING .
  5. Remove the 4 nuts and the strut tower cross brace.
    6. Fig 1: Locating Strut Tower Cross Brace & Nuts
    GF0000372Courtesy of FORD MOTOR CO.
  6. Remove the RH and LH valve covers. For additional information, refer to Valve Cover - RH  and Valve Cover - LH .
  7. Loosen the 4 coolant pump pulley bolts.
    8. Fig 2: Locating Coolant Pump Pulley Bolts
    GF0000393Courtesy of FORD MOTOR CO.
  8. Remove the accessory drive belt, the 2 accessory drive belt idler pulleys and the accessory drive belt tensioner. For additional information, refer to ACCESSORY DRIVE .
  9. Remove the 4 bolts and the coolant pump pulley.
  10. Remove the SC drive belt, SC drive belt tensioner and the 3 SC drive belt idler pulleys. For additional information, refer to ACCESSORY DRIVE .
  11. Remove the thermostat housing. For additional information, refer to ENGINE COOLING .
  12. Remove the crankshaft front seal. For additional information, refer to Crankshaft Front Seal .
  13. Disconnect the 2 coolant vent hoses from the intake manifold.
  14. Disconnect the 2 upper radiator hoses from the intake manifold.
  15. Disconnect the coolant hoses from the Charge Air Cooler (CAC).
  16. Disconnect the lower radiator hose assembly from the coolant pump, radiator, oil filter adapter and the coolant tube assembly (located above the generator).
    • Remove the lower radiator hose assembly from the vehicle.
  17. Disconnect the A/C pressure transducer electrical connector.
  18. Remove the power steering tube bracket nut from the generator stud bolt.
  19. Remove the power steering tube bracket bolt from the engine front cover.
  20. Remove the 2 bolts from the power steering reservoir bracket.
  21. Remove the 3 bolts and position the power steering pump and reservoir assembly aside.
  22. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
  23. Install the Engine Lifting Bracket.
    24. Fig 3: Identifying Special Tool 303-D087
    GF0000164Courtesy of FORD MOTOR CO.
  24. Install the Engine Lifting Bracket.
    25. Fig 4: Identifying Special Tool 303-D087
    GF0000165Courtesy of FORD MOTOR CO.
    NOTE: The heavy duty Engine Support Bar (303-F070) must be used with the draw screws from the light duty Engine Support Bar (303-F072). This will provide enough clearance between the SC and the Engine Support Bar, and enough clearance between the draw screw and the vehicle hood.
  25. Install the Engine Support Bars.
    • Remove the LH and RH engine support insulator nuts.
    • Using the Engine Support Bars, raise the engine.
    26. Fig 5: Raising Engine Using Special Tools (303-F072) & (303-F070)
    GF0000394Courtesy of FORD MOTOR CO.
  26. Remove the nut and disconnect the B+ wire terminal from the generator.
  27. Disconnect the generator electrical connector.
  28. Detach the wiring harness retainer from the oil pan stud bolt.
  29. Remove the nut and the wire harness retainer bracket from the oil pan stud bolt.
  30. Remove the stud bolt, 2 bolts and the generator.
  31. Disconnect the coolant hose from the oil filter adapter.
    32. NOTE: If metal or aluminum material is present in the oil cooler, mechanical concerns exist. Failure to correct these concerns may cause engine failure. To diagnose mechanical concerns, refer to ENGINE SYSTEM - GENERAL INFORMATION .
  32. Remove the 6 bolts and the oil cooler.
    • Discard the gaskets.
    • Inspect the oil cooler.
  33. Drain the engine oil.
    • Tighten the drain plug to 26 Nm (19 lb-ft).
  34. Remove and discard the engine oil filter.
  35. Remove the 3 coolant tube assembly bolts.
  36. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and the 2 wiring harness pin-type retainers.
  37. Remove the 8 bolts and the oil filter adapter.
    • Discard the gasket.
  38. Remove the 2 oil pan-to-engine front cover bolts and the 2 oil pan-to-engine front cover stud bolts.
  39. Remove the 4 bolts and the coolant pump.
    • Discard the gasket.
  40. Remove the 16 bolts and the engine front cover.
    • Remove and discard the engine front cover gaskets.
      • 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 all traces of old sealant.
    • Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    • Inspect the mating surfaces.
    41. Fig 6: Inspecting Mating Surfaces
    GF0000395Courtesy of FORD MOTOR CO.
scientia non olet · About LEMON Manuals