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HOMESERVICE MANUALSFORD2004ECONOLINE E150, VAN CARGO, 4.6 WREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 221 (ENGINE - 4.2L)IN-VEHICLE REPAIRENGINE FRONT COVERREMOVAL
2004 Ford Econoline E150, Van Cargo, 4.6 W

Engine Front Cover: Removal

2004 Ford Econoline E150, Van Cargo, 4.6 WSECTION Removal
WARNING: This page is about a different car, the 2003 Ford Econoline. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect the battery ground cable. For additional information refer to BATTERY, MOUNTING AND CABLES .
  2. Remove the water pump (8501). For additional information, refer to ENGINE COOLING .
  3. Raise and support the vehicle.
  4. Remove the crankshaft pulley. For additional information, refer to CRANKSHAFT PULLEY .
  5. Disconnect the wiring at the crankshaft position (CKP) sensor (6C315).
    Fig 1: Disconnect Wiring At Crankshaft Position (CKP) Sensor
    G01535867Courtesy of FORD MOTOR CO.
  6. At the front of the oil pan (6675), remove a bolt from the left and right side of the oil pan.
    Fig 2: Removing Oil Pan Bolts
    G01535868Courtesy of FORD MOTOR CO.
  7. Lower the vehicle.
  8. Remove the camshaft synchronizer. For additional information, refer to CAMSHAFT SYNCHRONIZER (4.2L) .
  9. Remove the accessory drive belt idler pulley.
    Fig 3: Removing Accessory Drive Belt Idler Pulley
    G01535869Courtesy of FORD MOTOR CO.
  10. Remove the accessory drive belt tensioner.
    Fig 4: Removing Accessory Drive Belt Tensioner
    G01535870Courtesy of FORD MOTOR CO.
  11. Remove and discard the water pump mounting studs.
    Fig 5: Removing Water Pump Mounting Studs
    G01535871Courtesy of FORD MOTOR CO.
  12. Remove the crankshaft front oil seal. For additional information, refer to CRANKSHAFT FRONT OIL SEAL .
  13. Remove the front cover and the front cover gasket.
    1. Remove the stud bolts.
    2. Remove the bolt.
      3. CAUTION: The cap screw is hidden; make sure to remove it or the front cover will be damaged.
    3. Remove the cap screw.
    4. Slide the front cover and the front cover gasket off the dowels. Discard the engine front cover gasket.
      Fig 6: Removing Engine Front Cover
      G01535872Courtesy of FORD MOTOR CO.
      5. CAUTION: Do not use a fiber disk to clean this surface. Fibers from the disk could get into the oil pan and oil, and clog the oil bypass valve.
    5. Clean all gasket mating surfaces.
      • Pack the exposed portion of the oil pan with shop towels.
      • Clean and inspect the gasket surface of the front cover.
      • Clean all gasket surfaces that require RTV with metal surface cleaner.
      • Clean and inspect the water pump gasket surfaces.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.