LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2000 >> Contour SE, 2.0 3, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1904 (Engine - 5.4L (3V) - F250 & F350) >> In-Vehicle Servicing >> Engine Front Cover >> Installation

Engine Front Cover: Installation

WARNING: This page is about a different car, the 2007 Ford Pickup and 2007 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
    NOTE: If the engine front cover is 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. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation.
    Fig 1: Applying Bead Of Silicone Gasket And Sealant Along Cylinder Head-To-Cylinder Block Surface And Oil Pan-To-Cylinder Block Surface
    GF0002753Courtesy of FORD MOTOR CO.
  1. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface, at the locations shown.
  2. Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the fasteners finger tight.
    Fig 2: Installing Engine Front Cover Gasket
    GF0000367Courtesy of FORD MOTOR CO.
  3. Tighten the engine front cover fasteners in sequence in 2 stages.

    Stage 1: Tighten fasteners 1 through 15 to 25 Nm (18 lb-ft).

    Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft).

    Fig 3: Identifying Engine Front Cover Fasteners Tightening Sequence
    GF0002754Courtesy of FORD MOTOR CO.
    Item Part Number Description
    1 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    2 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    3 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    4 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    5 N806177 Bolts, Hex Flange Head Pilot, M8 x 1.25 x 50
    6 N808529 Stud, Hex Head Pilot, M10 x 1.5 x 1.5 x 103
    7 N808529 Stud, Hex Head Pilot, M10 x 1.5 x 1.5 x 103
    8 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    9 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    10 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    11 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    12 W709573 Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
    13 W709573 Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
    14 W709573 Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
    15 W706605 Bolt, Hex Head Pilot, M8 x 1.25 x 56
  4. Loosely install the bolts, then tighten the bolts in 2 stages, in the sequence shown.
    • Stage 1: Tighten to 20 N.m (15 lb-ft).
    • Stage 2: Tighten an additional 60 degrees.
    Fig 4: Identifying Tightening Sequence Of Front Oil Pan Bolts
    G03920544Courtesy of FORD MOTOR CO.
  5. Install the CKP sensor and the bolt.
    • Tighten to 10 N.m (89 lb-in).
  6. Connect the CKP sensor electrical connector.
  7. Position the A/C compressor and install the 3 bolts.
    • Tighten to 25 N.m (18 lb-ft).
    Fig 5: Locating Bolt Access Holes For A/C Compressor
    G03919912Courtesy of FORD MOTOR CO.
  8. Position the power steering pump assembly and install the 3 bolts.
    • Tighten to 25 N.m (18 lb-ft).
  9. Position the air cleaner outlet tube support bracket and install the 2 nuts.
    • Tighten to 25 N.m (18 lb-ft).
    Fig 6: Locating Air Cleaner Outlet Tube Support Bracket Bolt
    GF0005524Courtesy of FORD MOTOR CO.
  10. Position the starter wiring harness support bracket and install the nut.
    • Tighten to 10 N.m (89 lb-in).
    Fig 7: Identifying Cooler Tube/Electrical Harness Support Bracket Bolt
    G03919905Courtesy of FORD MOTOR CO.
    11. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.
  11. Using a new O-ring seal, install the RH CMP sensor and the bolt.
    • Tighten to 10 N.m (89 lb-in).
  12. Connect the RH CMP sensor electrical connector.
    13. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.
    Fig 8: Identifying RH CMP Sensor Electrical Connector
    G03919909Courtesy of FORD MOTOR CO.
  13. Using a new O-ring seal, install the LH CMP sensor and the bolt.
    • Tighten to 10 N.m (89 lb-in).
  14. Connect the LH CMP sensor electrical connector.
    Fig 9: Identifying LH CMP Sensor Electrical Connector
    G03919847Courtesy of FORD MOTOR CO.
  15. Install the RH and LH radio ignition interference capacitors and the 2 nuts.
    • Tighten to 10 N.m (89 lb-in).
    16. NOTE: LH shown, RH similar.
    Fig 10: Locating Radio Interference Capacitor Electrical Connectors
    G03885209Courtesy of FORD MOTOR CO.
  16. Connect the radio ignition interference capacitor electrical connectors.
  17. Install the accessory drive belt tensioner and the 3 bolts.
    • Tighten to 25 N.m (18 lb-ft).
  18. Install the coolant pump pulley and the 4 bolts.
    • Tighten to 25 N.m (18 lb-ft).
  19. Install the accessory drive idler pulley and the bolt.
    • Tighten to 25 N.m (18 lb-ft).
  20. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
    Fig 11: Locating Crankshaft Front Seal
    G03881970Courtesy of FORD MOTOR CO.
  21. Using the special tools, install a new crankshaft front seal into the engine front cover.
    Fig 12: Installing Crankshaft Front Seal Using Special Tools
    G03919891Courtesy of FORD MOTOR CO.
    22. NOTE: 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. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 13: Applying Silicone Gasket And Sealant To Woodruff Key Slot On Crankshaft Pulley
    G03919877Courtesy of FORD MOTOR CO.
  22. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
  23. Use the special tool to install the crankshaft pulley.
    Fig 14: Installing Crankshaft Pulley Using Special Tool
    G03919878Courtesy of FORD MOTOR CO.
  24. Tighten the new crankshaft pulley bolt in 4 stages.
    • Stage 1: Tighten to 90 N.m (66 lb-ft).
    • Stage 2: Loosen 360 degrees.
    • Stage 3: Tighten to 50 N.m (37 lb-ft).
    • Stage 4: Tighten an additional 90 degrees.
    Fig 15: Identifying Crankshaft Pulley Bolt Tightening Sequence
    GF0002723Courtesy of FORD MOTOR CO.
  25. Rotate the tensioner clockwise and install the accessory drive belt.
    Fig 16: Rotating Tensioner Clockwise And Installing Accessory Drive Belt
    GF0000336Courtesy of FORD MOTOR CO.
  26. Install the RH valve cover. For additional information, refer to Valve Cover - RH  in this article.
  27. Install the LH valve cover. For additional information, refer to Valve Cover - LH  in this article.
  28. Install the engine cooling fan. For additional information, refer to ENGINE COOLING article.
  29. Fill the crankcase with clean engine oil.
scientia non olet · About LEMON Manuals