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HOMESERVICE MANUALSFORD2004ECONOLINE E150, VAN CARGO, 4.6 WREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 780 (ENGINE)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 2005 Mercury Montego, 2005 Ford Freestyle, and 2005 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: 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, can cause engine failure.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  3. Remove the crankshaft front seal. For additional information, refer to LOWER END COMPONENTS - EXPLODED VIEW  and CRANKSHAFT FRONT SEAL .
  4. Remove the LH and RH valve covers. For additional information, refer to VALVE COVER - LH  and VALVE COVER - RH .
  5. Remove the bolt and the accessory drive belt tensioner.
  6. Remove the 3 power steering pump nuts and position the power steering pump and fluid reservoir aside.
  7. Disconnect the crankshaft position (CKP) sensor electrical connector.
  8. Disconnect the camshaft position (CMP) sensor electrical connector.
  9. Remove the 2 generator-to-engine front cover stud nuts.
  10. Remove the 2 generator-to-engine front cover studs.
  11. Remove the 3 pin-type retainers and the radiator splash shield.
  12. Remove the 2 A/C compressor bolts and the 2 A/C compressor nuts.
    • Support the A/C compressor with mechanic's wire.
  13. Remove the 2 A/C compressor bracket-to-engine front cover bolts.
  14. Remove the nut and detach the ground wire from the engine front cover stud bolt.
  15. Remove the 2 oil pan-to-front cover bolts.
    Fig 1: Removing Oil Pan-To-Front Cover Bolts
    G03990116Courtesy of FORD MOTOR CO.
  16. Remove the 15 bolts, stud bolt and the engine front cover.
    • Remove and discard the gaskets.
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.