Engine Front Cover

WARNING: This page is about a different variant/trim than selected.

SPECIAL TOOLS

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

MATERIAL SPECIFICATIONS

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

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
Recover the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .
Remove the accessory drive belt and the power steering belt. For additional information, refer to ACCESSORY DRIVE - 3.5L .
Remove the LH halfshaft and the intermediate shaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .
If equipped, remove the 6 screws and the underbody shield.

Fig 1: Location of Underbody Cover Shield Screws
Courtesy of FORD MOTOR CO.
Disconnect the power steering cooler tube and drain the power steering fluid into a suitable drain pan.

Fig 2: Location of Power Steering Cooler Tube
Courtesy of FORD MOTOR CO.
Drain the cooling system. For additional information, refer to ENGINE COOLING .
Remove the degas bottle. For additional information, refer to ENGINE COOLING .
Remove the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - 3.5L .
Remove the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
Disconnect the 2 engine wiring harness electrical connectors.

Fig 3: Location of Engine Wiring Harness Electrical Connectors
Courtesy of FORD MOTOR CO.
Detach the 2 wiring harness retainers from transmission mount and the battery tray bracket.

Fig 4: Location of Wiring Harness Retainers At Transmission Mount And Battery Tray Bracket
Courtesy of FORD MOTOR CO.
Remove the 2 nuts and the battery cables from the positive battery cable.

Fig 5: Location of Battery Cables Of Positive Battery Cable With Nuts
Courtesy of FORD MOTOR CO.
Remove the bolt and position aside the ground wire.

Fig 6: Location of Battery Bolt
Courtesy of FORD MOTOR CO.
Disconnect the vacuum hose and the Evaporative Emission (EVAP) tube from the upper intake manifold.

Fig 7: Location of Vacuum Hose And Evaporative Emission (EVAP) Tube Clamp
Courtesy of FORD MOTOR CO.
Disconnect the upper radiator hose, lower radiator hose and 2 heater hoses from the thermostat housing.

Fig 8: Location of Upper Radiator Hose, Lower Radiator Hose And Heater Hoses At Thermostat Housing
Courtesy of FORD MOTOR CO.
Disconnect the transaxle control cable from the control lever.

Fig 9: Location of Selector Lever Cable End
Courtesy of FORD MOTOR CO.
Remove the 3 nuts and position the transaxle control cable bracket aside.

Fig 10: Location of Selector Lever Cable Bracket Bolts And Nut
Courtesy of FORD MOTOR CO.
Remove the bolt and position the ground wire aside.

Fig 11: Location of Ground Wire And Bolt
Courtesy of FORD MOTOR CO.
If equipped, detach the engine block heater harness from the radiator support, power steering hose, A/C tube and the engine wiring harness.
Detach the coolant tube retainer clips from the A/C tube.

Fig 12: Location of Coolant Tube Retainer Clips On A/C Tube
Courtesy of FORD MOTOR CO.
Remove the nut and disconnect the A/C tube from the condenser.
- Discard the O-ring seals.
  
  Fig 13: Location of O-Ring Seals
  Courtesy of FORD MOTOR CO.
Remove the 2 A/C tube retaining clamp bolts.

Fig 14: Location of A/C Tube Retaining Clamp Bolts
Courtesy of FORD MOTOR CO.
Remove the A/C tube bracket bolt.

Fig 15: Location of A/C Tube Bracket Bolt
Courtesy of FORD MOTOR CO.
Remove the 2 nuts and disconnect the A/C tubes.
- Discard the O-ring seals.
  
  Fig 16: Location of O-Ring Seals
  Courtesy of FORD MOTOR CO.
Detach the 2 wiring harness retainers.

Fig 17: Location of Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
Disconnect the 2 engine wiring harness electrical connectors.

Fig 18: Location of Engine Control Wiring Harness Electrical Connectors
Courtesy of FORD MOTOR CO.
Remove the 2 wiring harness retainers from the LH valve cover stud bolts and position the wiring harness aside.

Fig 19: Location of Wiring Harness Retainers At LH Valve Cover Stud Bolts
Courtesy of FORD MOTOR CO.
Remove the oil level indicator.

Fig 20: Location of Oil Level Indicator
Courtesy of FORD MOTOR CO.
Disconnect the hose from the power steering reservoir.
- Detach the pin-type retainer from the engine mount brace.
  
  Fig 21: Location of Pin-Type Retainer At Engine Mount Brace
  Courtesy of FORD MOTOR CO.
Using a small screwdriver, release the retaining clip and detach the power steering reservoir from the cowl.

Fig 22: Releasing Retaining Clip And Detach Power Steering Reservoir From Cowl Using Small Screwdriver
Courtesy of FORD MOTOR CO.
Disconnect the fuel supply tube from the fuel rail. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .

Fig 23: Location of Fuel Supply Tube
Courtesy of FORD MOTOR CO.
Remove the bolt and the ground wire from the engine mount brace.

Fig 24: Location of Bolt And Ground Wire On Engine Mount Brace
Courtesy of FORD MOTOR CO.
Remove the 3 bolts and the engine mount brace.

Fig 25: Location of Bolts And Engine Mount Brace
Courtesy of FORD MOTOR CO.
Disconnect the PCM electrical connectors and pin-type retainers.

Fig 26: Location of PCM Electrical Connectors And Pin-Type Retainers
Courtesy of FORD MOTOR CO.
Remove the Power Steering Pressure (PSP) hose bracket bolt.

Fig 27: Location of Power Steering Pressure Hose Bracket Bolt
Courtesy of FORD MOTOR CO.
Remove and discard the PSP banjo bolt and the 2 seals from the steering gear.

Fig 28: Location of PSP Hose Banjo Bolt
Courtesy of FORD MOTOR CO.

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

Courtesy of FORD MOTOR CO.

Using a suitable holding device, hold the steering wheel in the straight-ahead position.
Remove the 2 nuts and the steering joint cover.

Fig 30: Location of Nuts And Steering Joint Cover
Courtesy of FORD MOTOR CO.

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 .

NOTE: Index-mark the steering column shaft position to the steering gear for reference during installation.

Remove the bolt and disconnect the steering column shaft from the steering gear.
- Discard the bolt.
  
  Fig 31: Location of Index Mark And Steering Column Shaft Mounting Bolt
  Courtesy of FORD MOTOR CO.
Remove the 4 screws and position the LH fender splash shield aside.

Fig 32: Location of Fender Splash Shield Mounting Screws
Courtesy of FORD MOTOR CO.
Remove the 6 pin-type retainers (4 shown in illustration) and the LH splash shield.

Fig 33: Location of LH Splash Shield And Pin-Type Retainers
Courtesy of FORD MOTOR CO.

NOTE: The steering gear-to-dash seal must be removed or it will be damaged when lowering the subframe.

Fig 34: Location of Steering Gear-To-Dash Seal Clips

Courtesy of FORD MOTOR CO.

Release the 4 clips and slide the steering gear-to-dash seal off of the steering gear and into the passenger compartment.
Disconnect the transaxle cooler hoses.

Fig 35: Location of Transaxle Cooler Hoses
Courtesy of FORD MOTOR CO.
Remove the drain plug and drain the engine oil.
- Install the drain plug and tighten to 27 Nm (20 lb-ft).
  
  Fig 36: Location of Drain Plug Mounting Bolt
  Courtesy of FORD MOTOR CO.
Remove and discard the engine oil filter.
Remove the 6 nuts and the Y-pipe assembly.
- Discard the gaskets and nuts.
  
  Fig 37: Location of Nuts And Y-Pipe Assembly
  Courtesy of FORD MOTOR CO.
All-Wheel Drive (AWD) vehicles

NOTE: Index-mark the driveshaft for installation.

Fig 38: Location of Driveshaft Bolts

Courtesy of FORD MOTOR CO.

Remove and discard the 4 bolts (3 shown in illustration) and support the driveshaft with a length of mechanic's wire.
All vehicles
Remove the engine roll restrictor-to-subframe through bolt.

Fig 39: Location of Engine Roll Restrictor-To-Subframe Bolt
Courtesy of FORD MOTOR CO.

NOTE: LH shown in illustration, RH similar.

Fig 40: Location of Cotter Pin And Nut On Tie-Rod Ends

Courtesy of FORD MOTOR CO.

Remove the cotter pins and nuts from the tie-rod ends.

NOTE: LH shown in illustration, RH similar.

Fig 41: Separating Tie-Rod Ends From Wheel Knuckles Using Tie-Rod End Remover

Courtesy of FORD MOTOR CO.

Using the Tie-Rod End Remover, separate the tie-rod ends from the steering knuckles.

NOTE: LH shown in illustration, RH similar.

Fig 42: Location of Stabilizer Bar Link Nut

Courtesy of FORD MOTOR CO.

Remove the nuts and separate the stabilizer bar links from the struts.
Using a wax pencil, mark the relationship of the front subframe to the underbody at the mounting locations.
Position the Powertrain Lift under the subframe assembly.

Fig 43: Identifying Powertrain Lift Under Subframe
Courtesy of FORD MOTOR CO.

NOTE: LH shown in illustration, RH similar.

Fig 44: Location of Subframe Bracket-To-Body Bolt

Courtesy of FORD MOTOR CO.

Remove the 4 subframe bracket-to-body bolts.

NOTE: LH shown in illustration, RH similar.

Fig 45: Location of Rear Subframe Nut And Subframe Bracket

Courtesy of FORD MOTOR CO.

Remove the 2 subframe nuts and the 2 subframe brackets.

NOTE: LH shown in illustration, RH similar.

Fig 46: Location of Front Subframe Nut

Courtesy of FORD MOTOR CO.

Remove the 2 front subframe nuts.
Using the Powertrain Lift, lower the subframe assembly from the vehicle.

Fig 47: Identifying Powertrain Lift Under Subframe
Courtesy of FORD MOTOR CO.

Front Wheel Drive (FWD) vehicles
Remove the 2 RH catalytic converter bracket bolts.

Fig 48: Location of Catalytic Converter-To-Bracket Bolts
Courtesy of FORD MOTOR CO.
Remove the 2 nuts and remove the RH catalytic converter bracket.

Fig 49: Location of Catalytic Converter Support Bracket Nuts
Courtesy of FORD MOTOR CO.

All vehicles

NOTE: Position a block of wood under the transaxle.

Fig 50: Installing Powertrain Lift And Adjustable Grip Arms

Courtesy of FORD MOTOR CO.

Install the Powertrain Lift and Adjustable Grip Arms.
Remove the transaxle support insulator through bolt.

Fig 51: Location of Transaxle Support Insulator Bolt And Nut
Courtesy of FORD MOTOR CO.
Remove the transaxle support insulator bracket bolt and the 2 nuts.

Fig 52: Location of Transaxle Support Insulator Bracket Bolt And Nuts
Courtesy of FORD MOTOR CO.
Remove the 4 engine mount nuts.
- Remove the 2 engine mount spacers.
  
  Fig 53: Location of Engine Mount Nuts
  Courtesy of FORD MOTOR CO.
Remove the nut, 2 bolts and the engine mount.

Fig 54: Location of Engine Mount Nut And Bolts
Courtesy of FORD MOTOR CO.
Lower the engine and transaxle assembly from the vehicle.
If equipped, detach the block heater wiring harness retainer from the upper intake manifold.

Fig 55: Location of Block Heater Wiring Harness Retainer At Upper Intake Manifold
Courtesy of FORD MOTOR CO.
If equipped, detach the block heater wiring harness retainers from the PSP hose and the power steering reservoir hose.

Fig 56: Location of Block Heater Wiring Harness Retainers At PSP Hose And Power Steering Reservoir Hose
Courtesy of FORD MOTOR CO.
Disconnect the PCV hose from the PCV valve.

Fig 57: Location of PCV Hose
Courtesy of FORD MOTOR CO.
Disconnect the Throttle Body (TB) electrical connector.

Fig 58: Location of Throttle Body (TB) Electrical Connector
Courtesy of FORD MOTOR CO.
Detach the wiring harness retainers from the upper intake manifold.

Fig 59: Location of Wiring Harness Retainers At Upper Intake Manifold
Courtesy of FORD MOTOR CO.
Remove the upper intake manifold support bracket bolt.

Fig 60: Location of Upper Intake Manifold Support Bracket Bolt
Courtesy of FORD MOTOR CO.

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.

Remove the 6 bolts and the upper intake manifold.
- Discard the gaskets.
  
  Fig 61: Location of Upper Intake Manifold Bolts
  Courtesy of FORD MOTOR CO.
Disconnect the RH Catalyst Monitor Sensor (CMS) electrical connector.

Fig 62: Location of RH Catalyst Monitor Sensor (CMS) Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the PSP switch electrical connector.

Fig 63: Location of PSP Switch Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the RH VCT solenoid electrical connector.

Fig 64: Location of RH Variable Camshaft Timing (VCT) Solenoid Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the 3 RH coil-on-plug electrical connectors.

Fig 65: Location of RH Coil-On-Plug Electrical Connectors
Courtesy of FORD MOTOR CO.
Detach all of the wiring harness retainers from the RH valve cover and stud bolts.
Disconnect the LH VCT solenoid electrical connector.

Fig 66: Location of LH VCT Solenoid Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the 3 LH coil-on-plug electrical connectors.

Fig 67: Location of LH Coil-On-Plug Electrical Connectors
Courtesy of FORD MOTOR CO.
Detach all of the wiring harness retainers from the LH valve cover and stud bolts.

NOTE: LH shown in illustration, RH similar.

Fig 68: Location of Coil-On-Plug Assemblies Bolts

Courtesy of FORD MOTOR CO.

Remove the 6 bolts and the 6 coil-on-plugs.
Detach the PSP hose retainer from the engine lifting eye.

Fig 69: Location of PSP Hose Retainer
Courtesy of FORD MOTOR CO.
Remove the PSP hose bracket nut and position the PSP hose aside.

Fig 70: Location of PSP Hose Bracket Nut
Courtesy of FORD MOTOR CO.
Remove the 2 nuts and the wiring harness retaining bracket.

Fig 71: Location of Nuts And Wiring Harness Retaining Bracket
Courtesy of FORD MOTOR CO.
Loosen the 9 stud bolts and remove the LH valve cover.
- Discard the gasket.
  
  Fig 72: Location of LH Valve Cover Stud Bolts
  Courtesy of FORD MOTOR CO.
Loosen the bolt, the 8 stud bolts and remove the RH valve cover.
- Discard the gasket.
  
  Fig 73: Location of RH Valve Cover Bolts
  Courtesy of FORD MOTOR CO.

NOTE: VCT solenoid seal removal shown in illustration, spark plug tube seal removal similar.

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).
  
  Fig 74: Removing Seal Using VCT Spark Plug Tube Seal Remover And Handle
  Courtesy of FORD MOTOR CO.
Remove the 3 bolts and position the power steering pump aside.

Fig 75: Location of Power Steering Pump Bolts
Courtesy of FORD MOTOR CO.
Remove the 3 bolts and the accessory drive belt tensioner.

Fig 76: Location of Bolts And Accessory Drive Belt Tensioner
Courtesy of FORD MOTOR CO.
Using the Strap Wrench, remove the crankshaft pulley bolt and washer.
- Discard the bolt.
  
  Fig 77: Location of Crankshaft Bolt And Washer
  Courtesy of FORD MOTOR CO.
Using the 3 Jaw Puller, remove the crankshaft pulley.

Fig 78: Identifying Crankshaft Damper
Courtesy of FORD MOTOR CO.
Using the Oil Seal Remover, remove and discard the crankshaft front seal.

Fig 79: Removing Crankshaft Front Seal
Courtesy of FORD MOTOR CO.
Remove the 2 bolts and the engine mount bracket.

Fig 80: Location of Engine Mount Bracket And Bolts
Courtesy of FORD MOTOR CO.

NOTE: Only use hand tools to remove the studs.

Fig 81: Location of Engine Mount Studs

Courtesy of FORD MOTOR CO.

Remove the 2 engine mount studs.
Remove the 3 bolts and the engine mount bracket.

Fig 82: Location of Engine Mount Bracket And Bolts
Courtesy of FORD MOTOR CO.
Remove the 22 engine front cover bolts.

Fig 83: Location of Engine Front Cover Bolts
Courtesy of FORD MOTOR CO.
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 84: Location of Engine Front Cover Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.

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.

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.

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.

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 Location of dowel pins are seated correctly in the cylinder block.