Engine Front Cover: Installation

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford Excursion, and 2004 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 four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, follow the directions provided on the packaging of the silicone gasket remover and the metal surface prep. 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

Courtesy of FORD MOTOR CO.

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.
Install the engine front cover with engine front cover gasket on the front cover to cylinder block dowel and loosely install the bolts.

Fig 2: Installing Engine Front Cover With Engine Front Cover Gasket On Front Cover To Cylinder Block Dowel
Courtesy of FORD MOTOR CO.

Tighten the engine front cover fasteners in sequence in three stages.

Stage 1: Tighten fasteners 1 through 7 to 25 Nm (18 lb-ft).

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

Stage 3: Tighten fasteners 8 through 15 to 48 Nm (35 lb-ft).

MATERIAL SPECIFICATIONS

Item	Part Number	Description
1	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
2	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
3	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
4	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
5	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
6	N808529	Stud, Hex Head Pilot, M10 x 1.5 x 59 - M10 x 1.5 x 30
7	N808529	Stud, Hex Head Pilot, M10 x 1.5 x 59 - M10 x 1.5 x 30
8	N808142	Screw and Washer, Hex Pilot, M10 x 1.5 x 57.5
9	N808142	Screw and Washer, Hex Pilot, M10 x 1.5 x 57.5
10	N808142	Screw and Washer, Hex Pilot, M10 x 1.5 x 57.5
11	N808140	Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 - M8 x 1.25 x 27
12	N808140	Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 - M8 x 1.25 x 27
13	N808140	Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 - M8 x 1.25 x 27
14	N808140	Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 - M8 x 1.25 x 27
15	N808140	Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 - M8 x 1.25 x 27

Fig 3: Tightening Engine Front Cover Fasteners In Sequence

Courtesy of FORD MOTOR CO.

Connect the CMP electrical connection.

Fig 4: Connecting CMP Electrical Connection
Courtesy of FORD MOTOR CO.
Install the bracket and the nut.

Fig 5: Installing Bracket And Nut
Courtesy of FORD MOTOR CO.
Install the bracket.

Fig 6: Installing Bracket
Courtesy of FORD MOTOR CO.
Position the radio interference capacitors and install the nuts.

Fig 7: Positioning Radio Interference Capacitors
Courtesy of FORD MOTOR CO.
Install the belt idler pulley and tighten the bolt.

Fig 8: Installing Belt Idler Pulley
Courtesy of FORD MOTOR CO.
Install a new crankshaft front seal. Refer to CRANKSHAFT FRONT SEAL .
Raise and support the vehicle. Refer to JACKING & LIFTING .
Loosely install the bolts, then tighten the bolts in the two stages, in the sequence shown.
- Stage 1: Tighten to 20 Nm (15 lb-ft).
- Stage 2: Tighten an additional 60 degrees.
  
  Fig 9: Tightening Bolts In Sequence
  Courtesy of FORD MOTOR CO.
Connect the CKP sensor electrical connector.

Fig 10: Connecting CKP Sensor Electrical Connector
Courtesy of FORD MOTOR CO.

NOTE: The front lower hole in the power steering pump is not used.

Fig 11: Positioning Power Steering Pump

Courtesy of FORD MOTOR CO.

Position the power steering pump and install the bolts.
Install the drain plug.

Fig 12: Installing Drain Plug
Courtesy of FORD MOTOR CO.
Lower the vehicle.
Install the valve covers. Refer to VALVE COVER LH and VALVE COVER RH .
Fill the engine with clean engine oil.
Install the water pump. Refer to ENGINE COOLING .
Install the radiator. Refer to ENGINE COOLING .
Connect the battery ground cable. Refer to BATTERY, MOUNTING AND CABLES .