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Home >> Ford >> 2005 >> Excursion 5.4 L, RWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 5 (Engine - 6.0L Diesel) >> In-Vehicle Repair >> Engine Front Cover >> Removal

Engine Front Cover: Removal

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

    All vehicles 

  1. Remove the intake manifold. For additional information, refer to INTAKE MANIFOLD  in this article.

    2. Early build vehicles 

  2. Disconnect the exhaust pressure tube at the exhaust.
    Fig 1: Disconnecting Exhaust Pressure Tube Exhaust
    G03906851Courtesy of FORD MOTOR CO.
  3. Remove the nuts and the exhaust pressure bracket assembly.
    Fig 2: Removing Nuts Exhaust Pressure Bracket Assembly
    G03906852Courtesy of FORD MOTOR CO.

    4. All vehicles 

    NOTE: Remove the thermostat housing only if a new front cover is being installed.
    Fig 3: Removing O-Ring
    G03887297Courtesy of FORD MOTOR CO.
  4. Remove the stud bolts and the thermostat housing.
    • Remove and discard the O-ring.
  5. Disconnect the engine coolant fill hose.
    Fig 4: Locating Heater Hose At Front Cover
    G03906854Courtesy of FORD MOTOR CO.
  6. Disconnect the lower radiator hose.
    Fig 5: Disconnecting Lower Radiator Hose
    G03906855Courtesy of FORD MOTOR CO.
  7. Remove the stator standoff bolt.
    Fig 6: Removing Stator Standoff Bolt
    G03906856Courtesy of FORD MOTOR CO.
    8. NOTE: Upper bolts shown, lower bolts similar.
    Fig 7: Removing Bolts
    G03906857Courtesy of FORD MOTOR CO.
  8. Remove the 4 bolts and position aside the power steering pump.
  9. Remove the bolts and the accessory drive belt tensioner.
    Fig 8: Removing Bolts Accessory Drive Belt Tensioner
    G03887304Courtesy of FORD MOTOR CO.
    10. NOTE: Remove the accessory drive pulleys, only if a new front cover is being installed.
    NOTE: Only one shown, others similar.
    Fig 9: Removing Bolts Accessory Drive Idler Pulleys
    G03887524Courtesy of FORD MOTOR CO.
  10. Remove the bolts and the accessory drive idler pulleys.
    11. NOTE: Remove the coolant pump pulley only if a new front cover is being installed.
    Fig 10: Removing Coolant Pump Pulley
    G03887305Courtesy of FORD MOTOR CO.
  11. Remove the coolant pump pulley.
  12. NOTE: Remove the coolant pump only if a new front cover is being installed.
    • Remove the bolts and the coolant pump. Remove and discard the O-ring.
    Fig 11: Removing Bolts Coolant Pump
    G03887306Courtesy of FORD MOTOR CO.
  13. Remove the nut and the battery cable bracket.
    Fig 12: Removing Nut Battery Cable Bracket
    G03906862Courtesy of FORD MOTOR CO.
  14. Remove the oil pump. For additional information, refer to OIL PUMP  in this article.
  15. Remove the bolts and the front cover.
    Fig 13: Removing Bolts Front Cover
    G03887307Courtesy of FORD MOTOR CO.
    16. CAUTION: Sealant is used where the crankcase and lower crankcase meet. Failure to cut the sealant could result in pulling the lower crankcase seal out while removing the front cover gasket.
  16. Use a thin blade scraper to cut the sealant where the crankcase and the lower crankcase meet. Remove and discard the front cover gasket.
    • Clean and inspect the sealing surfaces.
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