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Engine Front Cover: Installation

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 Ford Cutaway. 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 clean the sealing surfaces.
    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, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. 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: Locating Sealant Application Areas
    G03886057Courtesy 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 in Fig 1.
  2. Install the engine front cover with the engine front cover gasket on the engine front cover-to-cylinder block dowel and loosely install the bolts.
    Fig 2: Installing Engine Front Cover
    G03885297Courtesy of FORD MOTOR CO.
  3. Tighten the engine front cover fasteners in sequence in two stages.
    • Stage 1: Tighten fasteners 1 through 5 to 25 Nm (18 lb-ft).
    • Stage 2: Tighten fasteners 6 through 15 to 48 Nm (35 lb-ft).
      Fig 3: Tightening Engine Front Cover Fasteners In Sequence
      G03886447Courtesy of FORD MOTOR CO.
  4. Position the accessory drive belt idler pulley and install the bolt.
    Fig 4: View Of Belt Idler Pulley Bolt With Torque Specification
    G03885300Courtesy of FORD MOTOR CO.
  5. Connect the CMP electrical connector.
    Fig 5: Identifying Camshaft Position (CMP) Sensor Electrical Connector
    G03885221Courtesy of FORD MOTOR CO.
  6. Loosely install the bolts, then tighten the bolts in two stages, in the sequence shown in Fig 6.
    • Stage 1: Tighten to 20 Nm (15 lb-ft).
    • Stage 2: Tighten an additional 60 degrees.
      Fig 6: Installing Bolts In Two Stages
      G03886450Courtesy of FORD MOTOR CO.
  7. Connect the CKP sensor electrical connector.
    Fig 7: Locating CKP Sensor Electrical Connector
    G04612789Courtesy of FORD MOTOR CO.
  8. Install the bracket and connect the tubes. Install the retaining nut.
    Fig 8: Installing Retaining Nut
    G03886438Courtesy of FORD MOTOR CO.
  9. Connect the wiring harness to the bracket.
    Fig 9: Connecting Wiring Harness To Bracket
    G03886437Courtesy of FORD MOTOR CO.
    10. NOTE: The front lower hole in the power steering pump is not used.
    Fig 10: Positioning Power Steering Pump
    G03886454Courtesy of FORD MOTOR CO.
  10. Position the power steering pump and install the bolts.
  11. Install the oil drain plug.
  12. Install a new crankshaft front seal. For additional information, refer to CRANKSHAFT FRONT SEAL .
  13. Install the valve covers. For additional information, refer to VALVE COVER - LH  and VALVE COVER - RH .
  14. Install the coolant pump. For additional information, refer to ENGINE COOLING .
  15. Install the radiator. For additional information, refer to ENGINE COOLING .
  16. Fill the engine with clean engine oil.
  17. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
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