Engine Front Cover: Installation

WARNING: This page is about a different car, the 2018 Lincoln Navigator. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Only use a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) to clean the engine front cover. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean front cover.
- Clean the engine front cover using a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15, 000 rpm. Refer to: RTV Sealing Surface Cleaning and Preparation .
  Material: Motorcraft® Silicone Gasket Remover / ZC-30-A
  
  Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B
  
  Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B
- Thoroughly wash the engine front cover to remove any foreign material, including any abrasive particles created during the cleaning process.
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NOTE: Place clean, lint-free shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.

NOTE: Do not use wire brushes, power abrasive discs or 3M™ Roloc® Bristle Disk (2-in white part number 07528) to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. They also cause contamination that will cause premature engine failure. Remove all traces of the gasket.

Make sure that the mating faces of the engine block are clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation . Use the General Equipment: Plastic Scraper.

Material: Motorcraft® Silicone Gasket Remover / ZC-30-A

Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B

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Using the special tools, install the engine front cover to coolant pipe seal.Use Special Service Tool: 205-149 (T80T-4000-R) Installer, Spindle Bearing., 205-153 (T80T-4000-W) Handle.

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Install Special Service Tool: 307-399 Alignment Pins, Transmission Fluid Pump.

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- NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
  
  NOTE: The engine front cover and the 6 bolts must be installed within 4 minutes of the initial sealant application. The remainder of the engine front cover bolts must be installed and tightened within 35 minutes of the initial sealant application. If the time limits are exceeded, the sealant must be removed, the sealing area cleaned and sealant reapplied. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.
  
  Apply a 4.0 mm (0.16 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover sealing surfaces including the inner bolt bosses.
  
  Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
- Apply a 5.5 mm (0.21 in) bead of Motorcraft® High Performance Engine RTV Silicone to the oil pan-to-cylinder block joint and the cylinder head-to-cylinder block joint areas of the engine front cover in places as indicated.
  Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
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NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.

Install the engine front cover and the bolts.

Torque: 27 lb.in (3 Nm)

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Remove Special Service Tool: 307-399 Alignment Pins, Transmission Fluid Pump.

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Install the engine front cover bolts. Tighten in the sequence shown in 2 stages.
Torque:

Stage 1: Tighten bolts 1 thru 24 to: 177 lb.in (20 Nm)

Stage 2: Tighten bolt 1 thru 24 an additional: 45°

Fig 1: Engine Front Cover Tightening Sequence
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With clean oil, lubricate and position the oil pump electrical connector seal.

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NOTE: If the oil pump electrical connector seal is not properly installed, it may result in oil leakage.

Using the special tool, install the oil pump electrical connector seal.Install Special Service Tool: 303-1663 Installer, VDOP Seal.

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NOTE: The front surface of the oil pump electrical connector seal will be level with the engine front cover recess.

Inspect the oil pump electrical connector seal for proper installation.

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Install the transmission cooler bracket stud.

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Position back the engine wiring harness. Position back the transmission cooler tube bracket and install the nut.
Torque: 106 lb.in (12 Nm)

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Connect the generator wiring to the engine front cover.

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Install the pin-type retainers and connect the oil pump electrical connector.

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Vehicles with late build oil pan
Attach the starter motor wiring harness and retainer to the oil pan.

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Vehicles with early build oil pan
Attach the starter motor wiring harness and retainer to the oil pan. Position the ground wire and install the bolt.
Torque: 18 lb.ft (25 Nm)

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All vehicles
Install the cabin heater coolant pump and bolts. Connect the electrical connector.
Torque: 62 lb.in (7 Nm)

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- Install the accessory drive belt tensioner and bolts.
  Torque: 18 lb.ft (25 Nm)
- Install the accessory drive belt idler pulley and bolt.
  Torque: 18 lb.ft (25 Nm)
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Install the generator stud.
Torque: 71 lb.in (8 Nm)

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Position back the generator. Install the nut and the bolt.
Torque: 35 lb.ft (48 Nm)

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NOTE: When installing the B+ terminal nut to the generator, finger-start the nut before tightening or component damage may occur.

Install the B+ wire and nut, position back the protective cover and connect the electrical connector.

Torque: 150 lb.in (17 Nm)

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Install the following items:
1. Install the crankshaft front seal. Refer to: Crankshaft Front Seal .
2. Install the coolant pump. Refer to: Coolant Pump .
3. Install the thermostat housing. Refer to:THERMOSTAT HOUSING .
4. Install the RH valve cover. Refer to: Valve Cover RH .
5. Install the LH valve cover. Refer to: Valve Cover LH .
6. Install the charge air cooler outlet pipe. Refer to:CHARGE AIR COOLER (CAC) OUTLET PIPE .
NOTE: Do not lubricate the engine oil filter seal.

Install a new engine oil filter.

Torque:

Stage 1: 44 lb.in (5 Nm)

Stage 2: 180°

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Slide the engine appearance cover into the retaining bracket and install the retainers.
Torque: 97 lb.in (11 Nm)

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Fill the engine with clean engine oil. Refer to: Specifications .
Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)

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Pressurize the fuel system pressure. Refer to: Fuel System Pressure Release .
After completing the repairs, perform the Misfire Monitor Neutral Profile Correction procedure using a diagnostic scan tool.