How to remove Engine front cover on 2005 ford explorer?

Engine Front Cover & Seal

Removal & Installation

4.0L Engine SOHC

1. Before servicing the vehicle, please familiarize yourself with safety procedures.
2. Disconnect the battery ground cable
3. Drain the cooling system.
4. Remove the crankshaft front seal.
5. Remove the 2 nuts and detach the power steering pressure hose from the front cover.
6. Remove the 5 oil pan-to-front cover bolts.
7. Release the clamp and disconnect the lower radiator hose.
8. Remove the bolt and the drive belt tensioner.
9. Release the clamp and disconnect the heater hose from the coolant pump.
10. Disconnect the crankshaft position (CKP) sensor electrical connector.
11. Disconnect the alternator electrical connectors and the wiring harness retainer.
12. Remove the 3 alternator bracket bolts and the alternator bracket.
13. Remove the 2 coil bracket-to-left accessory drive bracket bolts.
14. Remove the 4 bolts and the left accessory drive bracket.
15. Remove and discard the CKP sensor wiring harness retainers.
16. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
17. Release the clamp and disconnect the upper radiator hose from the thermostat housing.
18. Release the clamp and disconnect the heater hose from the thermostat housing.
    
    NOTE

    The bypass hose will be removed with the thermostat housing.
19. Release the bypass hose clamp from the coolant pump end.
20. Remove the 3 bolts and the thermostat housing.
    
    NOTE

    Note the positions of the stud bolts for installation reference
21. Remove the 10 bolts, the engine front cover and the gasket. Discard the gasket.
    
    
    

    

    Fig. Front cover removal, part 1-4.0L SOHC engine
    
    
    
    

    

    Fig. Front cover removal, part 2-4.0L SOHC engine
    
    
    
    

    

    Fig. Front cover removal-4.0L SOHC engine

To install:

WARNING

Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.

1. Clean and inspect the gasket mating surfaces. Use silicone gasket remover and metal surface prep and a plastic or wooden scraping tool. Follow the directions on the packaging.
2. Position the front cover gasket.
   
   WARNING

   If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
   
   
   
   
   

   

   Fig. Apply silicone gasket and sealant to the oil pan and engine block mating surfaces-4.0L SOHC engine
   
   
   
   

   

   Fig. Apply silicone gasket and sealant to the front cover in 2 places-4.0L SOHC engine
3. Apply silicone gasket and sealant to the oil pan and engine block mating surfaces.
4. Apply silicone gasket and sealant to the front cover in 2 places.
   
   NOTE

   Make sure the stud bolts are installed in their original positions.
5. Position the front cover and install the 10 bolts. Tighten to 14 ft. lbs. (19 Nm).
   
   NOTE

   Make sure the coolant bypass hose is attached to the coolant pump.
6. Position the thermostat housing and install the 3 bolts. Tighten to 71 inch lbs. (11 Nm).
7. Position the bypass hose clamp.
8. Connect the upper radiator hose to the thermostat housing and position the clamp.
9. Connect the heater hose to the thermostat housing and position the clamp.
10. Connect the ECT sensor electrical connector.
11. Install new wiring harness retainers and position the CKP sensor wiring.
12. Connect the CKP sensor electrical connector.
13. Position the left accessory drive bracket and install the 4 bolts. Tighten to 31 ft. lbs. (42 Nm).
14. Install the 2 coil bracket-to-left accessory drive bracket bolts. Tighten to 89 inch lbs. (10 Nm).
15. Position the alternator bracket and install the 3 bolts. Tighten to 31 ft. lbs. (42 Nm).
16. Connect the alternator electrical connectors and the wiring harness retainer. Tighten to 71 inch lbs. (8 Nm).
17. Connect the heater hose to the coolant pump and position the clamp.
18. Position the drive belt tensioner and install the bolt. Tighten to 35 ft. lbs. (47 Nm).
19. Connect the lower radiator hose and position the clamp.
20. Install the 5 oil pan-to-front cover bolts. Tighten to 80 inch lbs. (9 Nm).
21. Position the power steering pressure tube and install the 2 nuts. Tighten to 13 ft lbs. (18 Nm).
22. Install the crankshaft front seal.
23. Connect the battery ground cable.
24. Fill the engine cooling system.

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