2006 Ford Freestar BaseFACTORY OEM SERVICE PROCEDURE

Engine Front Cover: Removal

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 AND LIFTING .
  2. Remove the generator. For additional information, refer to GENERATOR AND REGULATOR .
  3. Remove the coolant pump. For additional information, refer to ENGINE COOLING .
  4. Remove the crankcase position (CKP) sensor. For additional information, refer to ELECTRONIC ENGINE CONTROLS .
  5. Remove the camshaft synchronizer. For additional information, refer to ELECTRONIC ENGINE CONTROLS .
  6. Remove the generator brace bolt and the generator mounting bracket.
  7. Remove the 3 accessory drive belt tensioner bolts and the tensioner.
  8. Remove and discard the oil filter.
  9. If equipped, remove the oil cooler. For additional information, refer to OIL COOLER  in this article.
  10. Disconnect the RH front anti-lock brake wheel sensor electrical connector.
    Fig 1: Locating Anti-Lock Brake Wheel Sensor Electrical Connector
    G04003912Courtesy of FORD MOTOR CO.
  11. Position a safety stand under the RH side of the subframe.
    Fig 2: Locating Safety Stand Under RH Side Of Subframe
    G04660328Courtesy of FORD MOTOR CO.
  12. Remove the bolts lower the RH side of the subframe 50.8 mm (2 in).
    Fig 3: Locating Bolts At Lower RH Side Of Subframe
    G04003914Courtesy of FORD MOTOR CO.
  13. Remove the crankshaft pulley bolt and washer.
  14. Using the special tools, remove the crankshaft pulley.
    Fig 4: Removing Crankshaft Pulley Using Special Tools (303-009) And (303-176)
    G04660330Courtesy of FORD MOTOR CO.
  15. Using the special tool, remove the front crankshaft front seal.
    Fig 5: Removing Front Crankshaft Seal Using Special Tool (303-409)
    G04660331Courtesy of FORD MOTOR CO.
  16. Raise the subframe into position, then install the bolts.
    Fig 6: Locating Bolts At Lower RH Side Of Subframe
    G04003914Courtesy of FORD MOTOR CO.
  17. Remove the 2 oil pan-to-engine front cover bolts.
  18. Disconnect the catalyst monitor sensor electrical connector.
    Fig 7: Locating Catalyst Monitor Sensor Electrical Connector
    G04660333Courtesy of FORD MOTOR CO.
  19. Remove the catalyst monitor sensor electrical connector mounting bracket.
    Fig 8: Locating Catalyst Monitor Sensor Electrical Connector Mounting Bracket Nut
    G04660334Courtesy of FORD MOTOR CO.
  20. Remove the 2 engine front cover stud bolts and the engine front cover bolt.
    21. CAUTION: The capscrew is hidden by the oil filter housing. Failure to remove this retainer will result in damage to the engine front cover.
  21. Remove the engine front cover capscrew.
    22. NOTE: Mark the studs so they can be reinstalled in their original location.
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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.